LawnMaster NPTGSP2617A User manual

SERVICE MANUAL
26cc 2-Cycle Grass Trimmer
NPTGSP2617A
Read all safety rules and instructions carefully before servicing this tool.
601 Regent Park Court Greenville, SC 29607, 1-866-384-8432

2
Section Page
CONTENTS
CONTENTS 2
SPECIFICATIONS 3-5
GENERAL SAFETY RULES 6
PARTS AND FEATURES 7-11
WIRING DIAGRAM AND MANAGEMENT 12
GENERAL TROUBLESHOOTING 13-21
AIR & FUEL SYSTEM 22-29
THROTTLE AND STARTER SYSTEM 30-34
NOPULL™ STARTER SYSTEM 35-38
26CC 2-CYCLE ENGINE 39
GEAR HEAD AND SPOOL 40-42
MANUFACTURER'S WARRANTYAND CONTACT 43

3
SPECIFICATIONS
TORQUE SPECIFICATIONS
Engine Size 2-Stroke / Full Crank
Engine Displacement Claimed / Rated 26cc / 25.4cm3
Ignition Capacitor Discharge Ignition (CDI)
Carburetor All Position Diaphragm Type With Primer Bulb
Air Filter Foam (Dry)
Engine Shut Off Auto-Reset
Throttle Control Variable Speed Trigger
Fuel / Oil Ratio 40 : 1
Fuel Tank Capacity 400 ml
Spark Plug Champion RCJ6Y
Rotor Air Gap 0.012”-0.015” (0.30-0.40 mm)
Spark Plug Gap 0.026” (0.65 mm)
Run Time on Full Tank 40 Minutes
UNIT SPECIFICATIONS
Engine
Fuel System
General
Application Description Torque Torque
(IN.LBS) (N.m)
Crankcase Apply a thermostable screw-thread glue onto the 4
VFUHZV0;DQGWKHQ¿[WKHFUDQNFDVHFRYHU 53-62 6-7
Cylinder to crankcase Apply a thermostable screw-thread glue onto the 4 screws (M5X20) and then tighten the screws securing
the cylinder to crankcase. 53-62 6-7
Spark plug to cylinder Pre-screw the spark plug to the cylinder, and then
tighten with a torque spanner. 115-137 13-15.5
Carburetor mount to
cylinder
Apply a thermostable screw-thread glue onto the 2
screws (M5X20) and tighten the screws securing the
carburetor mount to the cylinder. 35-44 4-5

4
SPECIFICATIONS
Flywheel to crankshaft Apply a thermostable screw-thread glue onto the FUDQNVKDIWWKUHDG3UHVFUHZWKHÀDQJHKH[DJRQQXW
(M8) and then tighten. 89-133 10-15
&OXWFKWRÀ\ZKHHO
Slide the corrugated washers onto the clutch bolts
(M6X21.5). Apply a thermostable screw-thread glue
onto the bolt thread head section. Install the bolts into
the clutch and tighten the bolts securing the clutch to
À\ZKHHO
71-89 8-10
Ignition coil to cylinder
Put the 2 screws (M5X20) through the ignition coil
and two spacers respectively. Apply a thermostable
screw-thread glue into the cylinder holes and then pre-
screw the 2 screws (M5X20). Insert a feeler gauge
RILQPPEHWZHHQWKHÀ\ZKHHODQGWKH
LJQLWLRQFRLO3UHVVGRZQWKHLJQLWLRQFRLOÀXVKDJDLQVW
the feeler gauge. Tighten the screws with a torque
spanner securing the ignition coil. Remove the feeler
gauge.
27-35 3-4
0XIÀHUWRFUDQNFDVH
3XWWKHEROWV0;WKURXJKWKHPXIÀHUDVVHPEO\
Apply a thermostable screw-thread glue onto the 2
EROWVDQGVHFXUHWKHPXIÀHUWRWKHFUDQNFDVHXVLQJ
the torque wrench.
62-71 7-8
Apply a thermostable screw-thread glue onto the
head section of 1 screw (M5X10). Pass the screw
WKURXJKWKHSRVLWLRQLQJKROHRQWKHPXIÀHUDVVHPEO\
KROGHUDQGWLJKWHQWKHVFUHZVHFXULQJWKHPXIÀHUWR
crankcase.
62-71 7-8
Pawl assembly to
crankshaft
Apply a thermostable screw-thread glue onto the
crankshaft thread. Pre-screw the pawl assembly to
crankshaft, and then tighten using the torque wrench. 62-80 7-9
$LU¿OWHUEDVHWR
carburetor Pre-screw the nuts (M5) with washers, and then tighten using the pneumatic tool. 27-35 3-4
Fuel tank bracket to
crankcase
Apply a thermostable screw-thread glue onto the
screw (M5X10) and pass it through the hole on fuel
tank bracket. Tighten the screw securing the fuel tank
bracket to crankcase.
27-35 3-4
Fuel tank to crankcase Apply a thermostable screw-thread glue onto the screw (M5X12). Pass it through the fuel tank hole.
Tighten the screw securing the fuel tank to crankcase. 27-35 3-4
Cylinder pressure plate
Apply a thermostable screw-thread glue onto the
screw (M5X10). Pass the screw through the cylinder
pressure plate hole and then tighten it onto the
cylinder.
27-35 3-4
Electric starter
assembly to crankcase
Align the 2 screw holes on the electric starter
assembly with the screw holes on crankcase. Tighten
the 2 screws (M5X60) securing the electric starter
assembly to crankcase.
27-35 3-4
Rear engine cover
assembly Tighten the 2 screws (ST3.9X30F) to secure the rear engine cover. 12-13 1.3-1.5

5
SPECIFICATIONS
Flywheel cover to
crankcase
Apply a thermostable screw-thread glue into the two
holes on crankcase. Tighten the 2 screws (M5X15)
VHFXULQJWKHÀ\ZKHHOFRYHUWRFUDQNFDVH
53-64 6-7.2
Lower engine cover
assembly
Place the lower engine cover onto crankcase. Tighten
the 3 screws (1*ST3.9X8, 2*M5X10) securing the
lower engine cover.
10-12
1.1-1.3 (for
1*ST3.9X8)
27-35
3-4 (for
2*M5X10)
Upper engine cover
assembly Tighten the 3 screws (M5X35) securing the upper engine cover. 27-35 3-4
Spark plug cover to
upper engine cover Tighten the screw (M5X10) securing the spark plug cover to upper engine cover. 27-35 3-4
Lower engine cover to
upper engine cover Tighten the screw (ST3.9X12) to secure the upper and ORZHUHQJLQHFRYHUVRQPXIÀHUVLGH 10-12 1.1-1.3
Right handle cover to
left handle cover Tighten the screws (ST3.9X16) to secure the right and left parts of the main handle. 10-12 1.1-1.3
Transmission yoke to
À\ZKHHOFRYHU
Apply a thermostable screw-thread glue into the four
VFUHZKROHVRQÀ\ZKHHOFRYHU7LJKWHQWKHVFUHZV
(M5X20) securing the transmission yoke. 53-62 6-7
Transmission yoke
assembly
Align the screw holes on the transmission yoke with
the screw holes on upper shaft. Tighten the screws
(M5X12 & M6X25) securing the transmission yoke to
upper shaft.
53-62 6-7
Trimming line cutting
blade assembly Tighten the screws (ST3.9X16) with washers to secure the trimming line cutting blade to the debris guard. 10-12 1.1-1.3
Ratchet to electric
starter assembly
Attach the ratchet to the electric starter lower cover.
Apply a thermostable screw-thread glue onto the head
section of the screw (M5X10) and tighten the screw
(M5X10) securing the ratchet.
27-35 3-4
Electric starter motor
assembly
Align the electric starter motor with the screw holes on
the electric starter upper cover. Apply a thermostable
screw-thread glue onto the head section of the screws
(M3X8) and tighten the screw securing the electric
motor.
4-6 0.5-0.7
Electric starter lower
and upper covers
assembly
Tighten the two screws (ST2.9X12F) securing the
lower and upper covers of the electric starter. 4-5 0.4-0.6

6
GENERAL SAFETY RULES
SAFETY
To protect the eyes from loose objects that could be thrown from the trimmer, always wear eye
protection with side shields marked to comply with ANSI Z87.1 when operating the trimmer.
Use only genuine manufacturer’s replacement parts for this product. Failure to do so may cause poor
¿WSRRUIXQFWLRQDQGSRVVLEOHLQMXU\
Scarfs, neckties, jewelry, jackets or other loose clothing and accessories should be avoided as they
can be caught on or become entangled in the trimmer. Secure hair so it is above shoulder level. To
protect your legs and feet, long pants and closed toed shoes should be worn.
To improve your grip and protect your hands, wear heavy-duty nonslip gloves.
7KHVRXQGOHYHOH[FHHGVG%$7RSUHYHQWKHDULQJGDPDJHDOZD\VZHDUVRXQGEDUULHUVHDUSOXJV
RUHDUPXIÀHUV
GENERAL TRIMMER SAFETY
Never operate the trimmer with a damaged guard or without the guard in place.
Avoid getting into direct contact with the line.
Always remember to keep both hands on the control handles when the engine is running.
'RQRWRSHUDWHWKHWULPPHULIWKHUHLVDIXHOOHDNDVLWLVD¿UHKD]DUG7KHIXHOOHDNPXVWEH¿[HGSULRU
to operating the trimmer.
Empty the fuel tank before storing if the trimmer will not be used for a few days.
Make sure the control handles have not accumulated oil and fuel and are clean and dry.
See Operator’s Manual for additional safety precautions.
WORK AREA
Operate only in well ventilated areas.
2EVHUYHDOOVDIHW\UHJXODWLRQVIRUWKHVDIHKDQGOLQJRIIXHO0L[DQGKDQGOHIXHOLQDFRQWDLQHUDSSURYHG
for storing gasoline. Wipe the trimmer dry if fuel is spilled on it. Always move away from the fueling
area before starting the engine.
Fuel the trimmer at least 10 ft. (3 m) from the place where you start the engine and operate the
trimmer.
NOTE: The trimmer head will rotate during carburetor adjustment. Wear protective equipment and
observe all safety instructions.

7
PARTS AND FEATURES
NPTGSP2617A EXPLODED VIEW

8
PARTS AND FEATURES
NPTGSP2617A PARTS LIST
Key
Number Application Description Quantity
1 321001101 Cleva 26cc 2-Cycle Engine 1
2 321001102 Throttle-body & Starter Set 1
2.1 321001103 Throttle-body Set 1
2.2 321001104 Starter Set 1
2.2.2 321001106 Starter Switch Assembly 1
2.2.3 321001107 Stop Switch Set 1
2.2.4 321001108 PCB Assembly 1
3 321001109 Handle Spacer 2
4 141004102 Cable Clamp 2
5 321001111 Clutch Assembly 1
5.1 321005103 Screw 4
6 321001113 Wire Lock 1
7 321001114 7.2V Lithium-Ion Battery 1
8 321005104 Aluminum Upper Trimmer Shaft 1
9 321001116 Assist Handle Assembly 1
9.1 321001117 Assist Handle 1
9.2 321001118 Handle Clasp 1
9.3 321001119 Ball Joint 1
9.4 321001120 Ball Socket 1
10 321002102 Shaft Connection Sleeve 1
11 321005105 Aluminum Lower Trimmer Shaft 1
12 321005106 Debris Guard Bracket 1
13 321001121 *HDU%R[ 1
13.1 321005107 Screw 1
13.2 321001112 Bolt 1
13.3 321001122 Bolt 1
14 321001124 Cover Plate 1
15 321001125 Debris Guard 1
16 321001126 Rapid Reload Head Assembly 1
16.1 321001129 Rapid Reload Spool Spring 1
17 321001127 Charger 1
18 221003102 Shoulder Strap (Available Separately) 1
19 321001128 Shoulder Strap Clasp (Available Separately) 1
20 321004122 0+H[DJRQ6RFNHW:UHQFK 1
21 321004121 0+H[DJRQ6RFNHW:UHQFK 1
22 321004123 Open End Wrench 1
23 321004124 Socket Wrench 1

9
PARTS AND FEATURES
EXPLODED VIEW 26CC 2-CYCLE ENGINE

10
PARTS AND FEATURES
26CC 2-CYCLE ENGINE PART LIST
Key
Number Application Description Quantity
1 321001130 Spark Plug Cover 1
2 321001131 Nut 1
3 321001132 Upper Engine Cover 1
4 321001133 Logo 1
5 321001134 $LU'HÀHFWRU 1
6 321002109 Cylinder Air Damper 1
7 321001136 0XIÀHU&RYHU 1
8 321001137 0XIÀHU 1
9 321001138 Insulation Sheet 1
10 321001139 Spark Plug 1
11 321002110 Gasket 1
12 321002111 Ignition Coil Assembly 1
13 321002112 Positive Stop Switch Cable 1
14 321002113 Spacer Set 4
15 321002114 Cylinder 1
16 321002115 Gasket 1
17 321001143 Pawl Assembly 1
18 321002116 Electric Starter Assembly 1
19 321002117 Rear Engine Cover 1
20 321002118 Carburetor Mount Assembly 1
21 321002119 Washer 1
22 321002120 Carburetor 1
23 321001147 Air Filter Base 1
24 321001148 Air Filter 1
25 321001149 Air Filter Cover 1
26 321001150 Rotary Knob 1
27 321001151 Choke Lever 1
28 321001152 Fuel Cap Assembly 1
29 321002121 Fuel Tank Grommet 1
30 321002122 Fuel Tank 1
31 321002123 Fuel Tube 1
32 321002124 Fuel Tube 1
33 321002125 Fuel Line Filter 1
34 321001154 Rubber Pad 1
35 321001155 Fuel Tank Bracket 1
36 321002126 Negative Stop Switch Cable 1
37 321001156 Lower Engine Cover 1

11
38 321002127 Crankshaft Set 1
39 321002128 Piston Ring 2
40 321002129 Piston 1
41 321002130 Retainer Ring 2
42 321002131 Retainer Ring 2
43 321002132 Needle Bearing 1
44 321002133 Piston Pin 1
45 321002134 Crankcase Assembly 1
46 321002142 Flywheel 1
47 321002143 Flange Nut M8 1
48 311014125 Flat Key 1
49 321002145 Clutch Assembly 1
50 321002146 Washer 2
51 321002147 Corrugated Washer 2
52 321002148 Bolt 2
53 321002149 Flywheel Cover 1
54 321002150 Round Ring 2
55 321002151 Screw 2
56 321002152 Screw 3
57 321002153 Self-Tapping Screw 2
58 321002154 Screw 2
59 321002155 Lower Rear Engine Cover Plate 1
60 321002156 Heat Resistant Grommet 1
61 321001160 Screw 6
62 321001161 Self-Tapping Screw 2
63 321002157 Screw 2
64 321002158 Screw 4
65 321002159 Screw 6
66 321001163 Screw 2
67 321001164 Rubber Plug 1
68 321001165 Nut 2
69 321001166 Washer 5
70 321001162 Self-Tapping Screw 1
71 321001210 Screw 1
72 321005103 Screw 2
PARTS AND FEATURES

12
WIRING DIAGRAM AND MANAGEMENT
- IGNITION AND STARTING
2S Battery Pack Starter Switch (Self-reset)
Stop Switch (Self-reset)
3.5 Bullet Terminal
Ignition Coil
Spark Plug
Engine
Engine Body Engine Body
3.5 Bullet Terminal
NTC
NTC
RD
RD
BK
BK BK
BK BK
BK
RD
Bullet Terminal(BL)
Bullet Terminal(BL)
Electric
Motor
EngineHandle
lgnition
Handle
M
RD
J10 J9
J8
GND M+
M-
Battery
Connector
LED
Panel
Battery Connector
PCB ASSEMBLY
VCC’
Push-Start
Ignition

13
GENERAL TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
The electric motor does
not start, and the battery
LQGLFDWRU/('ÀDVKHVUHG
The battery is not fully
charged or not inserted
correctly.
Charge the battery fully and insert it
correctly.
The motor does not start,
and the battery indicator
/('ÀDVKHV\HOORZ
The battery is overheated. Allow the battery to cool to room temperature. Re-start the tool after about
30 minutes.
The motor does not start,
and the battery indicator
/('ÀDVKHVJUHHQ
Possible short circuit in the
electric motor or the motor
drive lines.
Check if there is a short circuit in the
electric motor or the motor drive lines
referring to page 36.
The motor does not start,
and the battery indicator
/('ÀDVKHVDOWHUQDWLYHO\
red and green.
The starting current is
H[FHVVLYHWKHHQJLQHRU
electric motor may be seized
or cannot rotate smoothly.
Check if the engine or the electric motor is
stuck and cannot rotate smoothly referring
to page 36.
The motor does not start,
and the battery indicator
LED is continuously on.
There is an open circuit from
the PCB output to the motor
connecting line.
Check if there is an open circuit occurs
from the PCB output to the motor
connecting line referring to page 36.
The motor starts, but the
engine does not start. The starter drive system is broken.
Remove the electric starter. Replace the
drive system.
If drive system of the starter is in good
condition, the engine may be broken.
The engine does not start.
No spark or weak spark.
Clean or replace the spark plug. Reset the
spark plug gap 0.026”±0.002” (0.65±0.05
mm).
Check the gap between ignition coil and
À\ZKHHO0DNHVXUHWKHJDSLV¶¶
0.015’’ (0.30-0.40mm).
7KHDLU¿OWHULVEORFNHG &OHDQWKHDLU¿OWHU
The fuel tank valve is
blocked. Remove the blockage or replace.
Incorrect lubricant/fuel. Use correct lubricant/fuel.
The fuel tube is blocked or
broken. Clean or replace.
Incorrect carburetor
adjustment. Re-adjust the carburetor.
The carburetor is blocked. Remove the blockage.
([FHVVLYHRLOLQFDUEXUHWRU Tighten the carburetor nut or replace the
carburetor washer.

14
GENERAL TROUBLESHOOTING
The engine stops during
operation.
No fuel. Add fuel to the fuel tank.
The fuel tube is blocked. Remove the blockage.
The carburetor nut loosens
and has air leakage. Tighten the carburetor nut or replace the carburetor washer.
No spark or weak spark.
Clean or replace the spark plug. Reset the
spark plug gap.
Check the gap between ignition coil and
À\ZKHHO0DNHVXUHWKHJDSLV¶¶
0.015’’ (0.30-0.40mm).
Abnormal engine
compression.
Check if the piston ring sinters and the
piston and piston ring wear status. Check
the carbon deposit status in combustor.
Check the wear status inside cylinder.
Check if the spark plug loosens. Check
WKHJDSEHWZHHQLJQLWLRQFRLODQGÀ\ZKHHO
Make sure the gap is 0.012’’-0.015’’ (0.30-
0.40mm).
7KHHQJLQHLVÀRRGHG
Remove the spark plug. Clip the fuel tube
for fuel entering. Press the start button to
remove the fuel inside the cylinder.
The engine has less power.
The choke lever is closed. Open the choke lever.
7KHDLU¿OWHULVEORFNHG &OHDQWKHDLU¿OWHU
7KHIXHO¿OWHULVEORFNHG Remove the blockage or replace.
Incorrect lubricant/fuel. Use correct lubricant/fuel.
Incorrect carburetor
adjustment. Re-adjust the carburetor.
Carburetor washer hardens. Replace.
The main nozzle of the
carburetor is blocked. Clean or replace the carburetor if necessary.
The spark plug is worn out. Replace with new spark plug.
The carburetor has air
leakage. Tighten the carburetor.
The fuel has been
contaminated with water. Empty tank and replace with clean fuel.
0XIÀHUKDVFDUERQGHSRVLW Remove the carbon deposit.
([KDXVWSRUWKDVFDUERQ
deposit. Remove the carbon deposit.
Piston ring sinters. Clean the ring groove or replace the piston
ring.
Cylinder worn. Replace the cylinder.
Piston and piston ring are
worn out. Replace.

15
GENERAL TROUBLESHOOTING
No spark.
Spark plug electrode is wet. Dry the spark plug.
Spark plug has carbon
deposit. Remove the carbon deposit.
Spark plug insulation is
broken. Replace the spark plug.
Spark plug gap is too big/
small. Adjust to 0.026”±0.002” (0.65±0.05 mm).
Spark plug electrode is burnt
out. Replace the spark plug.
High voltage line of the
ignition coil is broken. Replace the high voltage line.
Ignition coil is broken or
burnt out. Replace the ignition coil.
Poor contact of the high
voltage line and the jump
ring. Amend.
Spark plug cap is broken. Replace.
Engine will not start but
VSDUNSOXJ¿UHV
([FHVVIXHOLQVLGHVSDUN
plug.
Remove the spark plug. Clip the fuel tube
for fuel entering. Press the start button to
remove the fuel inside the cylinder.
Fuel is not clean, with water. Replace the fuel.
Cylinder and piston ring
wear. Replace.
The spark plug loosens. Tighten.
Crankcase has air leakage. Replace the gasket.
Cylinder has air leakage. Replace the gasket.
No fuel. Add fuel.
No fuel in primer bulb. Prime the bulb.
Engine is not choked. Engage the choke.
Fuel tank valve is blocked. Remove the blockage.
The engine cannot be
stopped.
The switch wire does not
connect. Connect the wire.
The switch is broken. Replace.
The clutch engages during
idle speed.
Clutch is damaged. Replace.
The free length of the clutch
spring is too long. Replace.
Clutch is off center. Replace.

16
GENERAL TROUBLESHOOTING
No load speed is not
stable/consistent.
Incorrect carburetor
adjustment. Re-adjust the carburetor.
The carburetor has an air
leakage. Replace or re-tighten.
Fuel tube is broken. Replace.
Crankcase washer has air
leakage. Replace.
Fuel seal has air leakage. Replace.
After releasing the throttle
lever, the trimmer head
continues to rotate.
Idle speed is too high. Adjust the engine.
Clutch spring is broken. Replace.
Clutch friction plate is
broken. Replace.
The engine accelerates,
but the trimmer head does
not rotate.
7KHD[OHURWDWLQJVSOLQHRU
the transmission yoke spline
is worn out. Replace.
Irregular vibration.
The trimmer head is not
balanced. Repair or replace.
The drive shaft is bent. Replace.
Worn bearings. Replace.
Clutch is off center. Replace.

17
GENERAL TROUBLESHOOTING
Ŷ5RWDWHDFRPSUHVVLRQJDXJHLQWRWKHVSDUNSOXJKROH)LJ
Place the choke lever in the RUN position. Engage the throttle
safety and throttle trigger together to open the throttle and the
choke lever in the on position. Lift the start button cover and
press the start button 3-5 times until the gauge needle reaches its
peak (stops moving). Engine compression should be >0.6MPa.
Ignition System (See Figs. 4-9)
Ŷ5HPRYHWKHXSSHUHQJLQHFRYHUE\UHPRYLQJWKHVFUHZVZLWKWKHSURYLGHGKH[ZUHQFKDQG
screwdriver (Fig. 4 - 6)
1
4
2
3
Fig. 5Fig. 4
Fig. 2Fig. 1
Engine Compression (See Figs. 1-3)
Low compression will cause erratic idling, low power, and hard starting when hot. To test the engine
compression:
Ŷ5HPRYHWKHVSDUNSOXJFRYHUXVLQJWKHSURYLGHGKH[ZUHQFK)LJ
Ŷ5HPRYHWKHVSDUNSOXJFDS)XOO\FRYHUWKHVSDUNSOXJXVLQJWKHSURYLGHGVRFNHWZUHQFK5RWDWH
the wrench counter-clockwise to remove the spark plug (Fig. 2).
Fig. 6




  




Fig. 3

18
GENERAL TROUBLESHOOTING
Feeler Gauge
Ŷ5HPRYHWKHVSDUNSOXJFRYHU5HPRYHWKHVSDUNSOXJFDSDQGWKHVSDUNSOXJ&KHFNDQGUHPRYH
the carbon deposit in the spark plug. The spark plug gap should be 0.65±0.05mm. Inspect the
electrodes for wear and deposits (Fig. 7).
Ŷ,QVWDOOWKHVSDUNSOXJLQWRWKHVSDUNSOXJFDS&RQWDFWWKHQHJDWLYHHOHFWURGHWRWKHDOXPLQXPSDUW
(Fig. 8).
Ŷ3UHVVWKHVWDUWEXWWRQWRFKHFNLIWKHVSDUNSOXJVSDUNV
Ŷ&KHFNWKHJDSEHWZHHQWKHURWRUDQGWKHLJQLWLRQFRLO0DNHVXUHWKHJDSLVEHWZHHQDQG
in. (0.30-0.40 mm) as instructed in step 3 of the Ignition Coil Replacement section (Fig. 9).
Fig. 8Fig. 7
Ignition Coil Replacement (See Figs. 10-11)
Ŷ5HPRYHWKHXSSHUHQJLQHFRYHU
Ŷ5HPRYHWKHVSDUNSOXJFRYHUDQGWKHVSDUNSOXJFDS5HPRYHWKHVFUHZV5HPRYHWKHLJQLWLRQ
coil and the washers (Fig. 10 - 11).
Fig. 11Fig. 10
Ŷ5HSODFHZLWKDQHZLJQLWLRQFRLO
Ŷ7RDGMXVWWKHJDSEHWZHHQWKHURWRUDQGWKHLJQLWLRQFRLO¿UVWLQVHUWDIHHOHUJDXJHRILQ
(0.35mm) between the rotor and the ignition coil, then rotate the rotor and align the magnetic pole
RIWKHURWRUZLWKWKHLJQLWLRQFRLO3UHVVGRZQWKHLJQLWLRQFRLOÀXVKDJDLQVWWKHIHHOHUJDXJH7LJKWHQ
WKHVFUHZVWR¿[WKHLJQLWLRQFRLO5RWDWHWKHURWRUFRXQWHUFORFNZLVHWRUHPRYHWKHIHHOHUJDXJH5H
check to ensure the gap is 0.012-0.015 in. (0.30-0.40 mm) (Fig. 9).
Outer Electrode
0.026 in. (0.65 mm)
Fig. 9

19
GENERAL TROUBLESHOOTING
Clutch Replacement (See Figs. 12-18)
Ŷ5HPRYHWKHVFUHZVWRUHPRYHWKHWUDQVPLVVLRQ\RNH)LJ
Ŷ5HPRYHWKHXSSHUHQJLQHFRYHU
Ŷ8QVFUHZWKHEROWVRQWKHFOXWFKDVVHPEO\XVLQJDQLPSDFWGULYHURUZUHQFK)LJ
Ŷ5HPRYHWKHEROWVDQGFRUUXJDWHGZDVKHUV7KHQUHPRYHWKHFOXWFKDQGÀDWZDVKHUV)LJ
Ŷ5HSODFHZLWKDQHZFOXWFK
Ŷ6OLGHWKHFRUUXJDWHGZDVKHUVRQWRWKHEROWV7KHQLQVWDOOWKHEROWVWRJHWKHUZLWKWKHFRUUXJDWHG
washers into the clutch, with the side of the clutch marked with the direction of rotation facing
upwards (Fig. 16).
Fig. 13
Fig. 15
Fig. 12
Fig. 14
Fig. 16
Bolts
Flat Washers
Corrugated Washers

20
GENERAL TROUBLESHOOTING
Flywheel (Rotor) Replacement (See Figs. 19-22)
Ŷ5HPRYHWKHFOXWFK
Ŷ5HPRYHWKHQXWXVLQJDQLPSDFWGULYHU)LJ
Ŷ5HPRYHWKHVFUHZVWRUHPRYHWKHÀ\ZKHHOFRYHU)LJ
Ŷ7KHÀ\ZKHHOFDQEHUHPRYHGE\DSXOOHU)LJ&KRRVHDQDSSURSULDWHSXOOHUWRUHPRYHWKH
À\ZKHHO%HIRUHXVLQJWKHSXOOHUURWDWHVFUHZURG 1counter-clockwise till it is 1/4 to 1/2 its length
through. Ensure screw rods 2 and 3are protruded longer than screw rod 1. Rotate screw rods 2
and 3clockwise into the corresponding threaded holes as shown in Fig. 21. Make sure screw rods
2and 3are level and in same length. Then use a spanner to rotate screw rod 1 clockwise until
WKHÀ\ZKHHOLVUHPRYHG5RWDWHVFUHZURGV 1 , 2and 3counter-clockwise to remove the puller
IURPWKHÀ\ZKHHO
Ŷ7XUQWKHFOXWFKXSVLGHGRZQDQGVOLGHWKHÀDWZDVKHUVRQWRWKHEROWV$SSO\WKHWKUHDGORFNLQJJOXH
for 3-5 screw threads and then re-install the clutch (Fig. 17 & 18).
Fig. 18Fig. 17
Fig. 19 Fig. 20