Vessel GT-3500GE Assembly instructions

ExplodedDiagramDrawing
HandleComponents-ExplodedDiagramDrawing
DamperUnit-PartsList
OPERATOR'S MANUAL
& SPARE PARTS LISTS

Note:
Engine Type
Displacement
Fuel Tank Capacity
Fuel Mixture Ratio
Revolution(idling)
Revolution(loaded, impact)
Revolution(non loaded, max)
Maximum Output
Maximum Torque
Compression Rate
Fuel Consumption Rate
: Two Stroke, Forced, Air Cooled, Single Cylinder
: 46.5cc, 43x32mm(Inner bore size x stroke)
: 1 liter
: 25:1(gasoline : 2 cycle oil)
: 2700 rpm 250
: 7120 rpm
: 9880 rpm
: 2.3 Ps/7500 rpm
: 0.34 kg-m/5500 rpm
: 7.1 : 1
: 380 g/Ps.h
Ignition Type
Spark Plug Type
: Electronic
: NGK BPMR6A
Vibration
(ISO8662)
Unloaded
Loaded
without damper
: 8.9 m/S2
: 19 m/S2
Noise
(ISO15744)
Idle
Loaded
: 74.6dBA (LpA)
: 104dBA (LpA)
Carburetor Type : Diaphragm
Impact Square Drive Size
Fastening Torque Range
Free Speed
: 25.4 mm(1")
: 1700Nm(Full Throttle : 1255ft. lbf)
950Nm(Half Throttle : 701ft. lbf)
: 1200 rpm
Capacity Bolt Diameter : 32 mm (1 1/4")
Weight Without fuel : without damper 19.5 kg (42.99 lbs.)
: with damper 21.3 kg (46.96 lbs.)
Overall Dimensions Length
Heitgh
Width
without damper
: 680 mm (28")
: 338 mm (13")
: 390 mm (15")
Accessories Hex Key Wrench
Spark Plug Wrench
Spanner
4mm 1pc.
5mm 1pc.
6mm 1pc.
1pc.
10-13mm 1pc.
with damper
: 680 mm (28")
: 346 mm (13")
: 390 mm (15")
with damper
: 2.3 m/S2
:11.6 m/S2

001
002
003
004
005
006
007
008
009
011
012
013
014
015
016
017
018
019
020
021
021
021
021
021
022
023
026
027
028
032
034
036
037
038
039
040
041
043
291
292
305
306
307
308
310
321
322
323
334
335
336
370
371
372
373
374
1
1
1
1
4
1
2
2
1
1
1
1
1
1
1
1
1
2
2
V
V
V
V
V
2
1
1
1
1
1
1
4
1
1
1
2
1
1
3
2
1
1
1
1
1
2
2
3
1
1
1
4
2
2
1
1
SPARK PLUG CAP ASS'Y
SPARK PLUG RUBBER COVER
SPARK PLUG BPMR6A
CYLINDER SET( INDEX NO.4, 6)
HEX. HOLE BOLT 5x18/S
CYLINDER GASKET
PISTON RING
PISTON PIN CIRCLIP
PISTON SET( INDEX NO.7, 8, AND 9)
NEEDLE BEARING, 1014125
CRANK SHAFT COMPLETE( INDEX NO. 11,12)
SMALL NUT 10
STARTER PAWL
STARTER PAWL SPRING
STOP RING E-5
STARTER PULLEY( INDEX NO.14, 15, 16, AND 17)
CRANK CASE GASKET
OIL SEAL 15257
BALL BEARING #6202 C3
CRANK SHAFT SHIM 0.05
CRANK SHAFT SHIM 0.10
CRANK SHAFT SHIM 0.15
CRANK SHAFT SHIM 0.20
CRANK SHAFT SHIM 0.30
CRANK SHAFT WASHER 0.5
WOOD-RUFF KEY 3x13x5
MAGNET ROTOR COMPLETE
SMALL WASHER 10
NUT 10
PRIMARY CORD GROMMET
PRIMARY CORD GROMMET
HEX. HOLE BOLT 6x20/S
CRANK CASE ASS'Y( INDEX NO.18, 19, 20, AND 37)
NUT 6
OUTER RECEIVER
PISTON PIN COLLER
IGNITOR COMPLETE
CORD CLAMP COMPLETE
HEX. HOLE BOLT 5x18/S
HEX. HOLE BOLT 5x14
CORD B180M
STOP SWITCH COMPLETE
RETAINER PLATE, STOP BUTTON
RUBBER COVER, STOP BUTTON
NUT, STOP BUTTON
WASHER, 5
S. WASHER, 5
SMALL WASHER, 5
S.WASHER, 8
FAN CASE COMPLETE
PISTON PIN
S. WASHER, 6
HEX. HOLE BOLT 6x45
HEX. HOLE BUTTON SCREW 6x35
IGNITION COIL ASS’Y
GROUND WIRE COMPLETE

withoutDamperUnit
Additionalpartsincomformto
"GASEMISSIONCONTROL"
appliedforUSAEPAphase1
(CARBTier1)=USAmarketonly.
Partsnumbersinparenthesis[]to
beappliedforthe2005orlater
productionparts.
・
・
・
ApprovedbyEMISSIONCONTROLDirective
2002/88/EC,97/68/EC
045
047
048
049
054
055
056
057
058
060
061
062
063
064
065
067
068
069
070
071
072
075
081
082
085
087
088
089
090
091
092
094
095
096
097
098
101
115
116
117
120
250
251
258
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
294
295
296
298
299
300
302
303
304
311
312
313
314
315
316
317
318
319
320
324
325
326
330
331
332
333
337
338
339
340
341
342
355
356
358
359
360
361
375
1
1
1
1
1
1
2
2
1
2
2
1
2
2
2
3
3
3
1
1
1
1
1
1
2
1
4
2
1
1
1
1
2
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
2
1
1
2
1
1
2
VALVE, ADJUSTMENT
BUTTON, ADJUSTMENT
BRACKET, ADJUSTMENT
BALL, ADJUSTMENT 4 IN DIA.
SPRING, ADJUSTMENT S3.8X0.6
FIXED PIN SP 2.5X16 FOR ADJUST BUTTON
HEX. CAP BUTTON BOLT M5X12
WASHER M5, SPRING
BRACKET FOR TAIL PIPE
HEX. CAP BUTTON BOLT M6X12
WASHER 2H-M6, JAGGED SPRING
COVER FOR WIRES
HEX. CAP BUTTON BOLT M6X16
WASHER M6, SPRING
HEX NUT M6
HEX. CAP THREAD-THROUGH BOLT M6X22
WASHER 2H-M6, JAGGED SPRING
HEX U-NUT M6
MUFFLER PROTECTOR
MUFFLER SET ( INDEX NO.49, 295)
THROTTLE WIRE COMPLETE 300mm
THROTTLE ARM
5X20 SCREW
SPECIAL NUT M5
HANDLE BRACKET
TANK CAP ASS'Y( INDEX NO.92, 303)
HANDLE DUMPER RUBBER
HEX HOLE BOLT 5 X30S
CLEANER BODY
CLEANER SPONGE
CLEANER CAP
BOLT, COVER FASTENING
HEX HOLE BOLT 5X60
AIR COVER
CONNECTOR CASE
THROTTLE LEVER ASS'Y
( INDEX NO.298,299,300 AND 319)
HANDLE FRAME ASS'Y
SPARK ARRESTER COMPLETE
(USA /EU MARKETS)
CARBURETOR SET(USA /EU MARKETS)
MUFFLER SET(USA /EU MARKETS)
CLUTCH ARM COMPLETE
CLUTCH SPRING
CLUTCH STEP BOLT
SPRIT PROTECTION TUBE 10x200L
TANK
TANK CAP D-ASS'Y
BLOW OVER CHECK BOARD
COLLAR 10
WASHER 1.6, BRANKE SHAKE
BOLT, COVER FASTENING
HEX. CAP BOLT M5x14
RIVET
TAIL PIPE(USA /EU MARKETS)
HEX.HOLE SCREW M6X6(USA /EU MARKET)
TAIL PIPE BRACKET(USA /EU MARKETS)
THROTTLE WIRE COMPLETE 4T
HEX. HOLE BOLT 5x20PS
1
2
2
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
1
2
1
1
4
1
1
1
1
6
3
1
1
4
4
4
2
8
8
8
4
16
16
16
1
HEX. HOLE BOLT 5x12S
HEX. HOLE BUTTON SCREW 6x65
WASHER 6
MUFFLER GASKET
U NUT 4
TAIL PIPE COMPLETE
SCREW 4x12
HEX. HOLE BOLT 5x12S
HEAT SHIELD
HEX. HOLE BOLT 5x20PS
TANK BRACKET
FUEL TANK CUSHION RUBBER
FUEL TANK CUSHION RUBBER
INLET MANIFOLD GASKET
CARB. INSULATOR SET( INDEX NO. 64, 65)
CARBURETOR GASKET
CARBURETOR SET( INDEX NO. 67, 68)
CHOKE LEVER 1565-30
NUT 10
INNER TOOTHED WASHER 10
PRIMING PUMP COMPLETE
COLLAR 5.8
S. WASHER 5
CLUTCH WASHER B 1.6
WAVE WASHER 10
FUEL PIPE 2.5x4x90
RETURN GROMMET
FUEL PIPE ASS'Y 3x5x230
CLIP, 6.3 DIA.
PUMP FILTER BODY ASS'Y
TANK CAP CHAIN
CUSHION RUBBER
TANK HOLDING METAL COMPLETE
HEX. HOLE BOLT 5x15WS
FUEL TANK, VERMILLION
ADJUST SPRING
WASHER 5
COMBI. BOX SPANNER 10x19, PLUS
CORD CLAMP COMPLETE
CORD CLAMP
RECOIL STARTER BODY ASS'Y
WASHER, SPRING M6
HEX. CAP BOLT M6x12
ANTI-VIBRATION SUPPORT HANDLE RUBBER COVERED
PIPE FOR PROTECTING TANK
HEX. CAP BUTTON BOLT M5x35
HEX. U-NUT M5
WASHER M5, SPRING
PLATE FOR HANDLE
HEX. CAP BUTTON BOLT M5x16
HEX U-NUT M5
WASHER M5, SPRING
BRACKET FOR SUPPORT HANDLE
HEX. CAP BUTTON BOLT M5X14
HEX U-NUT M5
WASHER M5, SPRING
ADJUSTMENT BASE COMPLETE
( INDEX NO. 272,273,274,276,277,278 AND 355)

121
122
123
125
126
127
376
140
141
142
143
144
145
146
147
148
149
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
327
328
329
377
2
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
3
ADJUST SPRING
(Applicable for Non Emission Control Parts)
LOW ADJUST SCREW
HIGH ADJUST SCREW
NEEDLE VALVE
VALVE SPRING
CONTROL LEVER
HINGE PIN
HINGE PIN SET SCREW
DIAPHRAGM GASKET
MATERING DIAPHRAGM COMPLETE
AIR PURGE COMPLETE
DIAPHRAGM COVER
SET SCREW
THROTTLE VALVE (USA/EU MARKETS)
STOP PLATE (USA/EU MARKETS)
VALVE SPRING (USA/EU MARKETS)
SHUTTER SCREW
SET SCREW
PUMP BODY
PUMP GASKET
PUMP DIAPHRAGM
INLET SCREEN
SWIVEL
STOP RING
THROTTLE SHAFT COMPLETE
THROTTLE SPRING
THROTTLE VALVE
STOP PLATE
CHOKE SPRING
STEEL BALL
CHOKE VALVE
CHOKE SHAFT
IDLE ADJUST SPRING
IDLE ADJUST SCREW
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
RECOIL STARTER BODY COMPLETE
STARTER ROPE REEL
RECOIL SPRING
STARTER HANDLE
STARTER HANDLE CAP
SET SCREW
STARTER ROPE

withoutDamperUnit
171 172 173 174 175 176 177 178 183 188 189 190 191 192 193 194 195 196 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216
217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 255 256 257
351 352 353 354 357
D-HANDLE ANTI-VIBRATION RUBBER COVERED FOOT REST SHORT 22mm HEX, CAP BUTTON BOLT M6X16 WASHER 2H-M6, JAGGED SPRING FOOT REST SHORT 15mm
1 1 4 4 1
1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 2 6 6 1 1 1 1 1 1 1 1 4 4 4
SNAP RING STW-16
SHAFT, BEARING COMPLETE ( INDEX NO.218 AND 219) BUSHING, BEARING SHAFT GEAR CLUSTER PLANETARY GEAR COMPLETE ( INDEX NO.221 AND 222) BUSHING, PLANETARY GEAR PLANETARY PIVOT PLANETARY SPACER GEAR SELECTOR COMPLETE ( INDEX NO.225 AND 226) SPIRAL PIN 5 IN DIA.X26, GEAR SELECTOR O-RING N14, GEAR SELECTOR GEAR FLANGE PACKING, GEAR FLANGE HEX. CAP BOLT M5X10 WASHER 2L-M5, JAGGED SPRING WASHER WW-16, SPRING LEVER, GEAR CHANGE RETAINER SPRING S3.8x7x0.6x6 STEEL BALL DIA.4 WASHER M6, SPRING HEX. CAP BOLT M6X20 GASKET, GEAR CASE PIN 4 IN DIA. X13.8 WASHER 2H-M6, JAGGED SPRING HEX. CAP BOLT M6X25 CLUTCH SUPPORT FLANGE COMPLETE (INDEX NO.242,243,244,245,246 AND 247) BEARING 16005, BALL SNAP RING IRTW-47 BEARING 6907, BALL SNAP RING IRTW-55 OIL SEAL SC35558 CLUTCH RING SNAP RING STW-25 WASHER 2H-M6, JAGGED SPRING SPRING WASHER M6 HEX. NUT M6
1 1 1 4 3 3 3 1 1 1 1 1 1 1 1 1 2 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
HAMMER HOUSING COMPLETE (INDEX NO.171, 172 AND 173) OIL SEAL VB35505 B
USHING, PRESS-IN TO INDEX NO.171
WASHER 2H-M8, JAGGED SPRING WASHER M8, SPRING HEX. CAP BOLT M8X45 U-NUT M8, HAMMER HOUSING HEX. CAP BOLT M8X50 FOOT REST LONG ANVIL COMPLETE ( INDEX NO.188, 189 AND 190) RING, RETAINER O-RING P18, RETAINER RING CENTRAL SHAFT SPRING, RETURN HAMMER COMPLETE ( INDEX NO.193, 194, AND 196) CAM PLATE BALL, ROLLER 13/32 DIA. PLUG CLUTCH BEARING NSK51104, THRUST SPACER THRUST GASKET, HAMMER HOUSING RING FLANGE COMPLETE ( INDEX NO.204, 205,206 AND 207) OIL SEAL SC30527 BEARING 6007VV, BALL BEARING 6006, BALL GASKET, RING FLANGE GEAR CASE COMP.( INDEX NO.209, 210, 211 AND 214) OIL POT PORT PF3/8-19 BEARING 16004, BALL BEARING 16003, BALL SNAP RING IRTW-35 BUSHING, SELECTOR SHAFT SHAFT, SELECTOR GEAR
MOLYBDENUM GREASE for Impact Mechanism use
GEAR OIL
The gearbox will take about 250 cc. APOLO OIL GEAR AP or equivalent for Automobile Gearbox. Make sure oil level is center or more of window. Sight of glass with Wrench in horizontal position. Refilling should be at every 3 months or at 10 hour operation. Depending on envoirnment , it will be quite often as it gets dirty soon.

IMPACTMECHANISM-EXPLODEDDIAGRAMDRAWING
withDamperUnit
HANDLECOMPONENTS-EXPLODEDDIAGRAMDRAWING
withDamperUnit
GEAR OIL The gearbox will take about 250 cc. APOLO OIL GEAR AP or equivalent for Automobile Gearbox. Make sure oil level is center or more of window. Sight of glass with Wrench in horizontal position. Refilling should be at every 3 months or at 10 hour operation. Depending on envoirnment , it will be quite often as it gets dirty soon.
MOLYBDENUM GREASE for Impact Mechanism use

DamperUnit-PartsList (Memorandum)