Craftsman 298.586190 User manual

MODEL NO.
298.586190::
Foi_q_iick :service or repair, take your Outboard .....
Motor toany: Sears Service Unit throughout the
U.S. and Canada., Each Service Unit is staffed
by trained technicians, using Sears approved .
parts and repair procedures to ensure that we .
meet our pledge to youJ'We service what we
Sell." Refe_ to the Iocat telephone directory for •
the Sears Unit nearest you, .
HOWTOOROER.EPAmPARTS.....
Refer 'to the identification Plate for the'chin- " ,
plete mode! number when requesting service or
replacement parts for your outboard motor.-
..... Warranty Service is avail_able by simply
All parts ]isted herein may beordered from. returningthe out,board motor Or etec-
ahy Sears, Roebuck and Co.
WHEN....... ORDERING REPAPR PARTS, AL-
WAY£ GIVE THE FOLLOWING INFORMA,
TION! : ::
_:1, Model:Number 3. Part Name
Part Number 4, Quantity
If the parts You need are not stocked locally,
your order will be electronically transmitted
to a Sears Repair Parts Distribution Center for: ::
expedited handling,
FULLONEYEARWARRANTYON
OUTBOARDMOTOR
For one year from the first day of use of :
this outboard motor, when all instruc-
tions and procedures detailed in the
Owner's Manual are followed, Sears
will repair defects in material or :
workmanship which appear in the oui_-_:
board motor, free of charge,
If the outboard motor is used for com-
mercial or rental purposes, this war-
ranty applies for only thirty days from
the first, day of use,
tronic trollin 9motor to the nearest Sears
service center in the United States Or
Canada. Warranty iS valid in country of
purchase.
This warranty gives you specific legal
rights, and yoLf may also have other
rights which vary from state to state.
SEARS,ROEBUCKANDCO.,
DEPARTMENT698/731A
Sears Tower. Chicago_ lL 60684
SEARSCANADAINC.
222 Jarvis St. Toronto, Ontario. canada

TABLE OF CONTENTS P seNo.
SPECIFICATIONS .......................................... I
OWNER'S RESPONSIBILITY ........... _ • , ............. :....... 2
MAINTENANCE .......................................... 4
"LUBRICATION GEAR HOUSING 4
MUFFLER INSPECTION • ..................... 4
PROLONGED STORAGE ................................. 4
OPERATIONS ............................................. 4
NEW AUTOMATIC CLUTCH • .................. 4
BOAT MOUNTING .................................. ....... 5
STEERING ADJUSTMENT ..... ........................... 5
2"CYCLE ENGINE FUEL MIXTURE ......................... 6
STARTING PROCEDURES_ . ................................. 6
STOPPING PROCEDURES ............ .......... ......... 6
FLOODING ........................................... 7
CARBURETOR ADJUSTMENTS ............................. 7
PROPELLER SHEAR PIN ................................. 7
IGNITION SYSTEM ............. ,.......................... 8
REMOVING MOTOR FROM BOAT • ........ 8
SALT WATER OPERATIONS .............................. 8
TROUBLE SHOOTING CHECK LIST .......................... 9
REPLACEMENT PARTS .................................... 10
ORDERING PROCEDURES ...................... Outside Back Cover
PRODUCT WARRANTY Outside Back Cover
SPECIFICATION:::,
Type of Engine ................. ..i,:/_!_;,:/. o. ,. , .Air Cooled 2-Cycle
Horsepower ............... '::"_:_;:_'-_,':?,_;::"':_i .... ".............. 3.00
Propeller Via. and Pitch ..... ;(!82mm xi30 mm) .. _7.177 x 5.127:
Lub. (Gear Hsg.) .... i;i_ _ "r
................... ::,:.. :,:..... ...... _ ...... SAE 90!
Fuel Mixture , ., 50 to 1 ratio Of regula,_-gr_ad_gasoine t62-cycle outward
lubricant or its equivalent BIAcertified!TC_W:2_ycle outboard lubridanti
Steering ........................ ,.,, =......... 243 Pivot Steering

........... IMPORTANT ..................
'_i _ • • • • i HH_ :: • • II •
•_ : :i : :i::H-:
Owner's Responsibility and Operat_gSafety Check List
.::. BE SURE TO READ AND DO THE:FOLLOWING BEFORE :
OPERATING YOUR OUTBOARD MOTOR
: SAFETY CHECK,LIST :......_ : :
1.: Learn and observe the t_oatingilawsof the U.S, Coast Guard, state. Ic.:at:author-
2. U,S. Coast Guard reguMtions req0i_:e the following: ":7::
; : a, Provide an approved life-Vest, tYPe 1,2 or 3, Personal Flotation Device for each
person in boat. (Encourage passengers to wear them,)
b. If the boat exceeds 16 feet, also carry a type 4, throwable Personal Flotation
Device. " •
3, Do not fill fuel tank with motor running or near any flame or lighted smoking
material. _ ,,::
:;: 4: When loading boat distribute the load evenly ,keep the 10ad low; don't overload;
don't stand in asmall boat. Take weather and water conditions into account.
5. Do not permit persons to ride on parts of the boat not designed for such use.
Standing, bow riding and seat back or gi_nWale riding can be especial|y dangerous. "=
:i: OWNER'S RESPONSIBILITY :
:6. Read owner's manual before running your new outboard motor, •:
•7, Before starting, make sure your motor' is!:seCurely mounted to boat transom with a
_! :i safew Chain: Tighten clamp stead handies_0:relyby hand,
8. Be sure to have pliers, screwdriver, spare'sp_tPk plugs, wrench, shear pins and cotter
_ins in boat whenever leaving shore,
:): 9, Be sure t_ohave an adequate supply of fuel (carry only inan approved container) on
:_ board; Use a good grade of regular gasoline with proper mixture, as cited in the
Specifications.
10. Occasionally check to be sure clamp stud handles on transom mounting bracket are
tight.
11. IN CASE OF AN EMERGENCY, THE ENGINE CAN BE STOPPED BY DEPRES: ::÷_
SING THE STOP BUTTON (IF SO EQUIPPED) OR PLACING:CHOKE KNOB IN
_:!!i FULL CHOKE POSITION ........ -- -:
12. Keep an alert i6ok0ut, Serious accidents have resulted from failure to use eyes.
13, Keep firef gh'tlng and lifesaving equipment in good €ondition and readily accessible
at all times, : . :
14. Good housekeeping is eveh more important afloat than ashore: Cleanliness dimin;
ishes the probability of fire and tripping hazards.
:TIPS FOR TRAILERING OR AUXILIARY USE..... -..... _
15. When launching or loading boat on a trailer, place your Outboard motor in tl_e
tilted storage position, Also when tra lering your boat and outboard mot6r, keep
outboard motor inupright (vertical) position on:the boat transom. Outboard
::motors,transp0rted, across :rough roads in the "tilt" position could cause trans0rn
...... iidam_;:br ::m0ul_tirig brackets to break off, losing your motor. If motor_must be:
iltra[i_b_i!!i_!_itiW!i:posJ:tli0n, aShort length of 2 x 4 should' be placed between the"
i_o_ ibrack"t and the:mot0i::lag. The motor leg shoiild then be firmly tied down
i•again:st :the, 2x:4: to ,prevent any possible damage. Similar precautions should be
!:takbn: ifOSing themoto r asan auxiliary power source for a sailboat o(Powe¥ _oat, I
gmotol_ as_an:auxiliary power source, the use of an auxi[iaryadjustabie
i: 'i motor:brackbt is recommended. •:•

MAJOR PARTS
FuelFillerCap
a.d Air VentScrew
StopBullon
FuelShut-offValve
Fuel SedimentBow]
and Filler
DualAutomaHcClutch
ReverseDrivingLock
Tilt Pin Adjustment
MufflerPipe
ExhaustOutlel
Propeller----
CollerPin
/
StarterHandle
ChokeLever
Power Head
SparkPlug
-SteeringHandle
ClampStudHandles
Brackel
DriveShaftPipe_
CavitalionPlale
Fill and DrainPlug
GearHousing
-Figure I
MAINTENANCE
1. FEATURE INFORMATION
a. This outboard motor has special design
features as shown in Figure 1,
b. Your selection of our Marine Products will
provide you with many hours of enjoyable
boating. To assure your complete satisfac-
tion on the investment you have just made,
we ask you to read this manual thoroughly
before going afloat. Acquaint yourself with
the particular areas of operation on your
outboard motor: as you read, the step-by-step
procedures. Keep in mind maximum Per-
formance is achieved only wher] the owner
or operator is completely familiar with the
operating instructions. :.....
c, Periodic servicing will be required, it is
recommended that you consult your Sears=
Service Center when service is necessary,
We will be happy to extend our facilities
and assure prompt service.
.Figure.2
Figure 3

MAINTENANCE
2. LUBRICATION _GEAR HOUSING
a. The Gear Housing hasbeen pre-lubricated at
the factory; however, the grease level should
be checked as follows using SAE 90 out-
board motor grease, tSee Figure 2).
(1) Prior to initial operation.
(2) After first four {4) hours of use.
(3) Recheck after every fifty (50) hours
running time.
(4) Replace with new |ubdcant at the end
of your outboard motor season. This
is important, as it removes any water
from the gear housing and prevents
possible corrosion to internal parts.
b. To Check, Drain or Fill gear housing, follow
these steps:
(1) Position outboard motor upright,
(2) Remove drain plug and washer, then
insert nozzle of gear lubricant tube
into hole. --
• _(3) Squeeze tube until lubricant is forced
out around tube.
(4) Replace plug and washer. Be sure plug
is tightened securely.
(5) To achieve complete drainage of',lubri-
cant. remove cotter pin, propeller and
shear pin from propeller shaft; also_
gear housing cover by Unscrewing 2
bolts,
(6) When lubricant has completely _ra_ned,
repJace parts and refill gear housing
using filling procedure above,
c. For best results, lubricate propeller shaft
with tithium grease every 30 to 60 days.
3. MUFFLER INSPECTION
a. Periodically remove '_miJffler cover- by un-
screwing screws and inspect for carbon
build-up ins_i.dethe muffler inlet and outlet,
the exhaust port andi:the combustion
"chamber of the cylinder; ,:Excessive carbon
will prevent drawing the maximum power
out of the engine. [see Figure 3).
b_ Care: should be exercised while cleaning
.away carbon tO prevent:i scratches to the
surface of the engine components and drop-
ping carbon inside of crankcase.
(3) The outboard motor should be
mounted on a stand vertically with
power head up for storage.
(4) Pull starter handle slowly until resist-
ance iS felt due to compression pres-
sure, then stop. Release starter tension
slowiy to prevent engine from revers-
ing rotation due to compression
pressure, This position will close both.
the intake and exhaust ports .for
storage.
(5) Drain and fill gear housing as outlined
under Lubrication of Gear Housing.
|Ref. 2)
(6) Wipe exterior completely with fresh
water cloth and then apply light coat-
ing of oil,
b. When starting anew season, always use fresh
gasoline. Last year's gasoline may have
varnish deposits that will plug the carbu-
retor jets. thus requiring acomplete over-
haul.
c. To plan for the coming season, we recom-
mend you contact your Sears Service
Center before the new season for any service
repair work required,
OPERATION
NEW AUTOMATIC CLUTCH
New automatic clutch. Based on a dual
centrifugal clutch design, it allows the out-
board prop to turn at very sJow speeds or
even come to a complete stop while the
engine continues operating efficiently. It
eliminates the need to shift gears by hand
and prevents the engine from overheating
and stalling at slow speeds.
When engine starts, motor is neutral. As
throttle increases, sub clutch engages. At
approx. 6 MPH, main clutch ehgages to
provide direct drive for cruising.
4. PROLONGED STORAGE
a. Tot store your= outboard- motor for pro=
longed ,storage, prepare outboard as fol-
lows:
(1) ' See paragraph on stopping procedures.
(Ref. 10) ''
(2) When removing outboard motor from
boat, a_tow all water to drain from
unit.

OPERATION
6. BOAT MOUNTING
a. Mount the motor on the center of the boat
transom (stern). (See Figure 4).
CAUTION
Hand tighten transom bracket and clamp
stud handles simultaneously. Do not use a
wrench or any other device that would
Cause damage to brackets. Occasionally
:check tO be sure lamp stud handles on
transom mounting bracket are tight.
(See Figure 5). !,
b. To obtain the best performance from your
outboard, the following boat transom speci_
fications are recommended: (See Figure 4).
Transom Angle {See View 3):
.... . ...... 12 to 15degrees
Transom Height (See View 4): 20.7 inches
c. The angle of the motor column is easily
adjusted by removing the Hitch Pin:and
changing the Tilt Lock Bracket Pin in the
five (5) different angle position holes
_located on either side of the right or left
Transom Mounting Brackets, Each angle
position elevates five (5) degrees. Try
center hole position first. (See Figure 6).
d. To find the correct angle positio n, make a
test run at full throttle with your usual
loading in the boat, Always stop motor to
change the Tilt Lock Bracket pin_ The c0r- Figure 5
,: rect angle position will have your boat
traveling with the bow slightly higher than _:
the-stern, but should not porpoise (bow
rises and falls rapidly and continuously). Be
sure Tilt Lock Bracket Pin is always pushed
completely through both Transom Mount-_
ing Brackets and Hitch Pin is secured,
----------------- WARNING
If the motor column is tilted too far out*
ward, the boat is likely to porpoise or
cavitate at full throttle, which can be
dangerous because across wind or a wave
could suddenly .deflect the boat into a
dangerous -turn. Ale00 if the motor
column is tilted too fa Tinward, the bow
of-the boat wilt dig in, which can: be
dangerous When crossing.a wak e or fin
rough _water,i '' Do not runmotor_ in, the.
St0_age position, (See -View.:1 and 2,
FigiJre 4) _. _,
e. Secure motor to boat with Safety :Chain.
Chain not included with motor. .
20,7""
View 4
• . ?
H
Figure 6
7. STEERING ADJUSTMENT
Tighten steering tension bolt using a spanner :
for desired steering eff0rt.(See Figure 6). ' _
CAUTION I
There is a possibility of losing bolt if
backed out too far,

OPERATION
8. 2-CYCLE ENGINE FUEL MIXTURE
Use a good grade of regular gasoline. (See mix-
ing table below.)
CAUTION
Always use BIA certified TC-W oil in the
50,1 ratio. Failure to do so may result in
excessive spark plug fouling,, piston
scoring, or bearing failure. Oonot unde[
any circumstances, use multigrade, such as
10W-30, or other automobile oils; •
if BIA certified oil is not available,'use
an SAE 30 or 40 2-cycle or outboardoil;-
We reserve the right to refuse warranty on
parts which are damaged when. using
improper fuels or lubricants.
.... .WARNING
Gasoline is highly f!amm;_ble. Always mix
in well ventilated area; :Do not fill tank
with motor running, n0r= near any flame
or while smoking. Be sure vent screws
and filler caps on tanks are finger tighte:
ned when transporting gasoline in the
trunk of your automobile to prevent
explosion.
U.S. Measure
-::i Regular
; _.!': Gasoline to be added
E: : In Gallons In Pints In Oz
1 0.16 2.6'
3 0.48 .:. 7.7
i_. FUEL 5 0.80-_::
MIXING .... 6
i: TABLE : ' ''''_.......r.....
I. :50:1 ':
I: MIXTUR E Regular AmoUnlof!:oil:
:" = Gasoline
! . In Liters In Liters
1 0i02 ;: :::
,': :,20 ' :
9, STARTING PROCEDURE (See Fig;7& 7A)
a. Open air vent screw located on fuel filler
cap by turning counterclockwise,
b. Open fuel shut-off valve.
c. Open throttle- grip to hatf throttle.
do Move choke lever to "On'* position.
WARNING
When stetting outboard, the boat wilt
move with a sudden burst of speed. Make
sure you are well seated so as not to lose
your balance with e fast start,
Figure 7
Figure 7A
Figure 8
e. Pull starter handle slowly until you feet
starter engage. Then pull with rapid
motion and allow the starter cord to
retract slowly. (See Figure 8).
f. After engine has started, gradually move
choke laver to "Off" position while
warming up the engine.
g. Let engine idle for approximately 3
minutes before moving throtUe grip to
"Fast" position.
10. STOPPING PROCEDURE
To stop engine, move throttle grip to "Slow"
position and press stop button,{See Figure 7A)

OPERATION
WARNING
In case of an Emergency, the engine can
be stopped by moving the Choke Lever to
Full Choke Position.
if the motor will not be operated for a
period of time, if it is to be removed from
the boat, or if it is to be tilted up, we
recommend the following practice to
prevent spitlage from the carburetor
throat and bow! and to prevent gum
formations in the carburetor during
storage:
1, Close fuel shut-off valve and air
vent screw at fuel filler cap.
2. Al!ow motor to run at idling speed
until it stops of its own accord,
indicating the carburetor has run
dry,
Figure 9
_Fl_Adjlsti!g _rew
1% FLOODING
To clear engine of excess fuel, move choke lever
to "Off" position and throttle grip to half
throttle position. Pull recoil starter handle
until engine starts and continues to run. Figure IO
12. CARBURETOR ADJUSTMENTS
a. Your motor has a idle adjusting screw and
the idle speed has been preset at the factory.
However, you may need to adjust the idle
speed using Idle Adjusting Screw. Turn the
Screw clockwise to increase motor speed .......
-and counter clockwise to decrease it. The
idle speed adjustment must be done with
'throttle grip at ful closed position and the
idle speed should be as low as possible while
:the engine runs steady. (See Figure 9)
b, Periodically check filter for dirtby unscrew*
.' ing Sediment Bowl. (See Figure 12) "
i3, PROPELLER SHEAR PIN & COTTER
PIN HOLDER
a. The Shear Pin is used for the purpose of
protecting the Drive Train and Gears. The
Shear Pin wil! not prevent the propeller
from becoming damaged when striking an
under water object. When shear Ipin is
broken, the engine will continue to run,
however, the propeller will not be rotating.
CAUTION
Stop engine immediately after shearing
pin to avoid possible damage to the engine.
b. To replace shear pin, shut off motor,
remove cotter pin with pliers and slip off
propeller. (See Figures 10 & t1).
c. Replace with new shear pin located in shear
pin and cotter pin holder. (See Figure 12).
Figure 12
7

OPERATION
14. ¸
C,
d.
FLYWHEEL MAGNETO IGNITION
SYSTEM WITH .TRANSISTERIZED
ELECTRONIC IGNITOR
The magneto ignition system consists of the
following component parts: Flywheel. Trar_-
sisterized Electronic Ignitor and Ignition Coil.
Inspect the following if engine fails or is
hard to start:
(1) Spark plug as often as necessary. Be
sure spark plug gap setting is .025"
tO.6mm).
(2) Gasoline fuel supply and fuel shut-
off valvesho01d be open.
{3) Carburetor being starved of fuel.
The correct spark plug for this motor is
NGK 8MR-6A or Campion RCJ-8,
To test ignition system, remove spark
plug and pl_E',ceagainst bare spot on meta_
part of motor away from cylinder spark,'
plug hole and then pull starter cord several
times. If a spar k bridges the plug gap. the: Figure 14
magneto is in good operating condition.
CENTER BOLT
Figure 13
WARNING
The high tension lead wire must be con-:
nected to the plug for this check. If there
is no spark,= have the ignition checked at
your Sears Service Center.
15. REMOVING MOTOR FROM BOAT
a. Always tilt motor by lifting on rear of
shroud. DO NOT PUSH DOWN ON THE
STEERING HANDLE. When removing the
motor from the boat. raise the outboard i;n
upward direction until the propeller clears
the transom. Hold the motor upright long
enough to allow alt_Water to drain from the
exhaust pipe, When yop find it difficult to
hold the;motor uprigllti tighten the Center
Bolt increasingly for desired effort. (See
Figure 13).
,_,; _,. WARNING .......
Although' the engine is air cooled, it is
possibleto burn your hands on the engine:
biock and upper portion of the cotumn.
Do not touch.
If the motor will not be operated for a
period of time. if it is to be removed
from the boat, or if it is to be tilted up_
we recommend the following practice to
prevent spil|age from the carburetor
throat and bowl end to prevent gum
formations in the carburetor during
storage:
1. Close fuel shut-off valve and air vent
"screw at fuel filler cap.
2. Allow motor to run at idling speed
until it Stops of its own accord, indi- "
caring the carburetor has run dry. .
.16. SALT WATER OPERATION " .- :
To materially increase the life of all exposed
parts and decorative finishes; follow the steps
indicated below.
a.. Always tilt your motor out of the water
when not in use.
b. Never leave the lower unit in salt-water
overnight. -
c. Wipe exterior completely with fresh water
cloth and then apply light coating of oil.
d. Lubricate propeller shaft occasionally with
awaterproof type of lubricant (Lithium
Grease), thus enabling the propeller to be
removed easily.
b. It may be necessary to rotate the motor to
one side before tilting the motor on the
transom tO remove leg from the water when_i e,' It is good practice when opereting in salt
.... installed on boats with thick transoms; .1water to inspect your .motor daily and to
c. Always carry outboard with the engine _apply a light coating of grease to any
above the lower unit'to prevent moisture _part or area that shows evidence of cot-:
from entering •the engine through the rosion or rust,
exhaust ports. : f. Always remove motor from boat ver-
:d_ Steering handle serves as carrying handle as tically, allowing water to drain from column
.... shown in Figure 14. before tilting the motor.

TROUBLE SHOOTING CHECK LIST
*Take your outboard motor into any one of over
2000 Searz Service Units.
XXFuel Tank Empty
X X X X Fue L ne KZnked or Pin_;hed
X X X Fuel Filter Dirty or Clogged
X X X " " X' vent Screw On Fue] Tank Fitter Cap Closed.' "
X X X X Carburetor Passages Clogged or Dirty *
X X X X Xi' ' incorrect Fuel-Oil Mixture
X X X X X Carburetor Out of Adjustment •
X X Engine Flooded ' • ' '
X X XX X Wrong Type Spark Ptug
X X X X x Defective or Fouled Spark Plug ,,i,.
X X ' • Defective Magneto , ,
X 'i" Spark Does Not Jump, Spark PJug Gap :_
"' X.... Engine Out of Time : o. ...
X. x .x" x •Transisterized Electronic _gnitor out of order _- * •
XXXXX Weak' 'Ignition Coil ''- " : : ' ' " *
X " ' 'X=' ' Spark Piug Lead Wire Not Secured '
X•× '_ •*
X X
" , .1 .X Propeller Bound by Foreign Objects (Fishing Line. Weeds. Etc.)
X : High Tension Lead-Salt Water Build Up
9
IMPORTANT INFORMATION
MODEL NUMBER:, 298.586190
SERIAL NUMBER
DATE OF PURCHASE
INSURE YOUR ENGINE
Many insurance companies including Allstate
InsuraNce offer protection contracts for your
boat and outboard engine_ Insurance covering
your own equipment againstr damage, theft,
etc., as well as liability insurance for property
damage and pe_'sonal injury to others is availa-
ble. It would be wise to contact your insurance
agen t for_ further information about adequate
protection.
DATE NO. HRS. USED
IDENTIFICATION PLATE
OPERATING?:LOG
GALS. FUeL USED DATE NO: HRS. USED GALS; FUEL USED

REPLACEMENT PARTS_
FOR!,,,_._
MODEL No.298.586190
IO

FIG.I ENGINE _
79_
29-
75
74
-27
9
8
3O
80
5
165
66
48
86
|'!

.!
FIG.I ENGINE
REENo,
_:o0i
1-002
1";003
1._004
1-005
1-006
t°-007:
t-OOE
1-009
1-010
1-011
1-012
._1-014
1-015
11017 "
1-020
1-024_
!-024
1 ;024
1,_024
'_ 1-o25
1-028
1-027
,1-029
:: 1-031_ :?:
.... 'I"032
1-033-
1-038 ;
1-039., I
1-048
1-055
1-065
1-006
1-067 :l
1-068 :]
• _ 1-070.:
1_074
,1_075
:1-078
1-079
1,080
l:'OG 1
:'_.I "085
l:-OGU
1:1o3....
P.P.No;
o10-1o201-2oi
157_04000-900
018-00546-200
002"10200"802
OI_-I0200:ZOZ
040-I0100-2_0
041_10100-201
039-02000-201
031-10100;210
037-10100;200
046-10242-800
068=02000-200
999-01020-300
996-66173-000
999-62101-004
1:59-21401-871
07!-02007-2]0
07.1.;02007-220
071_02007-230
07I=02007-240
999-61620_200
999-60153-000
o9o-lo2oo_202
072-.I0242_900
:107-20751-801
.198;01046_g00
155-21717-801
112_10242-200
055:_02501-200
99I_00100_001
19U-11109-200
256-01046-200
g90_11050-102
1992-0!050-04!
990-11060-302
992-10060-042
090_11040-162
990-11040-182
992-10040-042
990-11060-252
_92-I0060-042
992:10060-042
991-01060-021
992-01050-041
090-11050-102
992--ri0040--042
PARTS NAME
CYLI'NHER:-SH2OUP_
SPARE PLUG CAP ASS'Y
SPARS PLUG BHRSA
CYLINDEZiCONP. -"
CYLINDEI:_GASKET
PISTOH!.21B6
PISTOH R:IHO
PISTOH PIN CIRCLIF
_ISTOH ::
PISTORPIH IOX35 .
CEAHK"SHAFT COHP.. " .
VOOD-_UFF KEY 3Xi3X5
5ALL BEARIHO e6203
OIL SEAL 17307
HEEDL2 BEARING FIOIOB
rIGHITOR TTI-IE
:CRANK SHAFT SHIK o;|o
CRAEK.SHAFT SHIX.O.15
CRA#ESUAFT SHIH0.20
CRAHS SHAFT S9IH 0.30
BALLBEARING 16202
_IL SEAL 15307
_RAHE.CASE GAS[ET
_RANI:CrASEASS'y
IGBITION:COIL COHP.
CORD"CLAHP ASS Y
MAGNETO ROTOE:'COHP._
FAH:CASE -:
FLYVBEEL VASUER
FLYVHEEL HUT 10
CO_D CLARP L
SPAR[ PLUG RUBBER COVER E
SCREH 5X10
VASHE_ 5
SC_EV 6X30
S.VASHEK 6
SCREV 4X16
SC_EU 4118
S,UASGER 4
SCR£9 6X25
S.HASHER 6
S,VAS_E2 6
NUT 0 ..
VASHER 5-
SCREV 5X10
S.VAS_R 4
O'ty
1
!
1
I
1
1
1
1
t
1
1
11.
1
V
V
V
V
I
1
I
t!
1
1
1
1
1
1

FIG.2 TANK, CLUTCH & MUFFLER
102
\\
45
42
15
56
55
16
13
3O
Z2
78
24
28 29
31
61
13

FIG,2 TANKt CLUTCH & MUFFLER
REENo.
2-002
2-003
2-004
2-005
2-006
2-007
2-008
2-009
2-010
2-0It
2-012
2-013
2-014
2-015
2-010
2-017
2-OIG
2-019
2-020
2-02I
2-022
2-023
2-024
2-025
2-026
2-027
2-028
2-029
2-030
2+031
2-033
2-034
2-035
2-038
2-037
2-038
2-030
2-040
2-041
2-042
2-043
2-044
2-04S
2-04H
2-04?
2-048
2-049
2-050
2-052
2-053
2-054
2-055
2-050
2-059
2-060
2-001
2-082
2-063
2-004
2-085
2-066
2-087
2-068
2-069
2"070
2-071
2-072
2-073
2-074
2-075
2-070
2-077
2-07E
2-100
2-101
2-102
2-103
2-104
P.P.No.
595-35100-D02
630-35500-200
300-35505-200
305-35500-200
650-00801-200
82D-10201-20
790-1020t-210
788-10200-202
793-10200-201
401-35500-200
603-02101-803
653-10218-800
854-10201-201
965-34501-200
1655-10201-200
855-014tA-200
592-10201-900
594-00517-200
700-15008-!26
T00-14508-140
680-01004-200
021-35100-202
260-00503-203
170-I0218-800
180-02004-200
182-01004-200
403-02000-202
393-02500-201
U80-031t3-200
420-10201-900
347-01046-20!
210-35300-800
358-10212-200
290-10112-802
359-10212-203
357-10112-204
342-10205-220
085-02501-200
991-09100-00!
737-10100-200
716-10201-200
737-10201-200
727-10201-200
221-35500-200
228-35500-200
220-35300-200
1225-35500-200
i227-35500-200
i990-12050-452
i992-20050-042
992-00050-04_
i990-21080-222
i992-I0060-042
1991-01080-021
992-20060-012
990-21040-302
992-20040-042
990-11060-202
992-20060-042i
990-12040-122i
992-10040-042i
990-12050-122
992-10050-042i
990-12050-252i
992"I0060-042
990-22050-222
D92-10050-042i
992"02050-04|:
990-12060-121
992-00050-021
012-35500-200
011-35100-200
702_30200-200
330_35555-200
331-355550200
900_35555-200
338_35118-200
992-10050-012
PARTS NAME O't_
_TANK CAP AS$'Y I
TANK CAP GASKET 1
ENGINE COVED 1
CUSHION RUBBER 2
COLLAR 4
STARTER PAUL BASE l
STARTER PAWL SPRING 2
STARTER PAUL 2
STEP BOLT 2
FUEL TAHK 2
FUEL TANK RAnD CORP. 2
FUEL TAHX BRACKET COXP. 1
FBEL TAnK BRACKET 9 I
TAXE SUPPORT RUBBER I
FOEL TANK CUSHION RUBBER 2
FUEL TAHK CUSHIOE RUBBER 2
PET-COCK ASS'Y I
PET-COCR FIXIE9 NUT I
FUEL PIPE 5X8XI1U 1
FUEL PIPE 4.SXBX240 1
CLIP a3
PI_ HOLDER Z
STOP BUTTON COVER 1
STOP BUTTUX CORP, I
STOP BgTTOX FIXIRG NUT 2
SPECIAL S.UASNER 2
'IHLET RAnIFOLD GASKET ]
INLET XAHIFOLO 1
CLIP 7,5 I
AIR CLEANER ASS'Y 2
CLUTCH FLANGE I
CLUTCH SPRING COXP, 3
CLUTCH HASHER A3
CLUTCH ARE CORP. 3
CLUTCH HASHER B3
CLUTCH STEP BOLT 3
CLOTCII $PRIHG 3
FLYVHEEL VASHEE 2
FLYWHEEL NUT 10
HUFFLER GASKET 2
HgFFLER BODY A
XUFELEE GASKET 12
XUFPLER BODY H!2
HUFFLER PIPE GASKET ,1
HUFFLEE PIPE STAY AI
RUFFLER PIPE 1
HUFFLER PIPE BRACKET A I
RUFFLER PIPE BRACKET B 1
SCREW 5X45 4
S.UASHER 5 4
WASHER 5 4
SCREW 5X22 .... 2
S.VA_flEK 8:'., 251
HUT 6......... +, 2,
S.VASHEE O:: +2
SCREV 4X30 ..2
S.VASAER 4 :: 2
SCREW BX20' +2
S.gASHER 8 • - + 2
SCREV 4X12 +.7
S.VASEEE4 1-7
SCEEV 5X22 : 2
S.VASEER 5.,"'+.2
SCREW 0X25 . .' ,_ I
S.VASHER 6:!:
SCREW 5El2 ,''
S.WASHER 5 - -_ 3
BASHER 5 3
SCREW HX12 -3
SHALL HASHER 5 _: 2
SHEAR PIE .... - " 2
COTTER PIN _ i+ 2"
FUEL PIPE COIL +:' 2
RIGHT SIDE HARK '1
LEFT SIDE HARE 1
RAgE PLATE 1
STARTER HARK 2
S.VASEEK O314

FIG'S RECOIL STARTER
0--
13
t4
•18
• • 3•0
_;f.--26
•5 •
REENo, P.P,No,
3-000 750-10207-900
3-001 772-10207-200
3-002 774-10200-200
3-003 779-10200-203
3-000 783-01006-201
3-01I 780-10201-200
3L012 785-10207-201
3_013 833-10207-200
3-014 992-01040-011
3-Q15 773-10200-200
3-_17 990-11050-25!
3-018 778-10200-200
3-019 827-10200-20]
3-020 900-11050-122
3-021 992-10050-042
3-022 992-01050-041
3-023 902-10050-042
3-024 991-41050-022
3-026 788-10200-200
3-030 791-I0200-200
!,., :•
PARTS NAME
_ECOIL 3Tk_TEg ASS Y
RECOIL STARTEE BODY
STARTEg 20PE REEL
AECOIL SPEIEG •
STA£TE_ _OPE ''
20PE GUIOE
STA_TEZ HAHDLE
STAETEE EAEDLE CAP.
VASEZA 4 _"
PULLEyrsBAFT/OUT_I
SC_EV 5X25
££C0IL SPBIHG CASE
RECOIL SPRZNGHOLDEZ_
SCREV 5X12
S,VASHgR 5
VASHE= 5
S,VASEEE 5
CAP HOT 5
STARTER VASHER
STARTER BUSBIKG
• !Q'ty
=,t
11
:t
t
I1
1
t
1,
1
1
,].
2
2
1
!
!
,]
1

IG.4 CARBURETOR
0-- 38 12
f
/""
/-
_- 4o
17
30_ 21
31_ ......
REENo.
4-000
4-002
4-003
4-004
4-005
4-000
4-007
4-008
4-010
4-011
4-012
4-018
4-017
4-OF!
4-024
4-026
4-027
4-028
4-029
4-030
4-031_
:4-037
4-038
4-039
4-040
P.P.No.
455-20217-900
597-20110-200
595-20200-200
594_20202-200
619-20202-200
593-20202-200
592-2002T-920
591-2005T-200
623-21700-200
622-20217-200
561-20202-900
6O7-EOHO_200
599-gOO]T-740
606-20202-200
994-34040-106
605-20202-200
603-20400-200
_2B-20202-EOO
604-20!t0-200
629-20202-2001
02?-20400-200
571-20200-200
802-20420-200i
598-20202-200
5_8-2005T-gSO
:j-
%,,, _-•
PARTS NAME, i
,4
CARBgRETOR ASS'Y .
CABLE ADJUSTEE
BODYCAP ...........
TIIEOTTLE VALVE $PR]_Q ' _
TREOTTLE SPEING SEAT
JET NEEDLE CLIP ,i
JET HEEOLE ASS'Y 004
THROTTLE VALVE 0.5X1.5
ADJUST SPRIHG
ADJUST SCREV :.
OUTLET CLIP ASS'¥
FLOAT CHAHBER GASKET
HAIN JET fT4
FLOAT CHAXBER V/TNREAD
SCREV 4X10/S
CHOKE PIH
NEEDLE VALVE
FLOAT E_
FLOAT
DRAIN SCREV GASKET
DRAIN PLUG
HAN.IFOL_ SEAL
HEEDLE SEAT
CABLE ADJUSTER LOCK NUT
_EEDLH:JET .2095
O'ty
I
i
1
1
l
!
1'
!
1
!
. 1
l
l
I
2
!
!
1
l
1
l
t
!
116

FIG.5 HANDLE & BRACKET
7]6 14 15 |_
17
0
52 -54 45
47
22'
23 41 20
39
4O
31 37
•I•,7

FIG,5 HANDLE & BRACKET,
REF.No. P.P.No.
_, J ,,
5-000 570-35552-900
5-001 885-01058-800
5-005 200-35300-800
5-006 093-51042-002
5-BB? 999-61600-404
5-008 993-50020-002
5-009 185-35300-203
5-010 OBO-210UO-252
5-01! 992-10060-042
5-012 990-11050-202
5-013 992-10050-042
5-014 18t-35500-202
5-015 793-10200-201
5-016 992-O4080-B31
5-017 100-35552-800i
5-019 102-35500-200
5-020 ,990-21080-302
_5-021' 992-0'1080-041
5-022 991_010E0-021
5_023_ _ 992_1'0080-042;
5-024 134=r35500--201:
_5_025 "]'15--3530_'210
.-,_5-028.1 131-35308-200
5-027" t35-35500-20I
":-5-028 990-21060-I02
5-029 990-11050-162
5_030,.. 992-10050-042
5_031 13T-35500_20!
5_032 138-35500-201
5_033 992-10050-042
5-034 990-11050-122
5':035 139-35500-200
+5-038 t29_35100-200
'_5-037- 123-35500-201
5_038'_ 107_35t18_801
5-039: 106_35119_'80!
5"040 990-2]0U0-752
5-04! 108:35501_:_200
5-042 991-41060-022
5-043 /992-10060_042
5-044 g92-01060-041
5-045 871-35552-2U0
5-O45 8?2,_35552-290
5-047 873-35552-200
5-048 B74-35552:200
5-049 875-35552-'200
5-050 870-355527200
5-051, 879-35552-209
5-052 99BT11050-202
5-053 991-B1050-02|
5-054 877-355_2-200
5-055 578-35552-200
5-056 903-32201-200
PARTS NAME O'ty
TWIST 6RIP ASS'Y l
THROTTLE WIRE COHP. I
CLUTCH DRU# COEP. 1
STOP RtHG C42 I
BALL BEARING 160040D. 1
STOP RING C20 I
CLDTC_ CASE I
HEX. BOLT 8X25 2
$.VASHER B 2
SCREW 5X20 4
S.VASHER 5 4
HAHDLB STOPPER I
STEP BOLT ]
HAVE RASHER 81
5TEERIH6 HAHOLE COHP. 1
UAHDLE V_SBrE_ 2
_OLT 8X30 l
WASHER 51
_UT 8 1
$,VASHER 8 !
THRUST VASBER l
BRACKET 1
THRUST BRACKET 4
RETHRH CAH I
BOLT BXIO l:
SCREW 5X10
S,VASHER 5...... l
RETUXE CAH GUIDE 1
RETURK GUIDE PLATE 1
$.VASEER 54
SCREW 5XI2 .4
RETURB SPRIHG I
BRACKET PIH STOPPER A-I
5RAC£ET PIE Sl
CLAHP-BRACRET B COXP; !.
CLARP BRACKET A CBXP. 1.
BOLT 6X75 1_-
CLAHP BRACKET BgSBIUG 2
CAP HUT 61
S.VAS'HER U1
WASHER 6 I
!THROTTLE GRIP I
ITHROTTLE I_HER .PIPE l
THROTTLE HOLBER A1
THROTTLE HOLDER H!'
THROTTLE HOLDER COVER 1
:WIRE GUIDE : . I
:TAPPIHG_;SCREV ' "2
SCREW 5X20 ;: 2
HUT 5': 2
TttROTTLES_OPP'_R:: ,t
THROTTLE STOPPERSPRIHG I
VIRE CLAKPBA_P '+ I"
18

.....FIG.6 DRIVE SHAFT PiPE'!I_::_GEAR:;¢ASE'_:
/
•24
27
28
23
30
29
22
21
T
18
/
/
/
/
,/
/
19