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(3) Reassembling the crank case ass'y, piston set, and cylinder set
When press-fitting the Oil Seal TB12227 [63]<62> into the
Crank Case Ass'y [61]<60>, position the pressurizing spring
inside, and then fill the gap between the lips with Pyronoc
Universal No. 0 (Nippon Oil Corp.). Dispose of the oil seal
removed at disassembly, and always use a new oil seal.
Before mounting the Cylinder Set PN [19]<19>, be sure to
apply two-cycle engine oil to the Ball Bearing 6001 C3
[64]<63>, the large and small bearings at the ends of the
connecting rod, Piston Ring [56]<55>, and the outer surface
of the Piston Set PN [55]<54>.
When mounting the Piston Set PN [55]<54>, position it so that the exhaust mark (arrow) on the top of
the piston points to the muffler. When mounting the Cylinder Set PN [19]<19>, correctly align the
closed gap of the Piston Ring [56]<55> with the lock pin at the groove in the Piston Set PN [55]<54>,
and the Cylinder Set PN [19]<19> with the Piston Set PN [55]<54>. Otherwise, the Piston Ring
[56]<55> may be easily damaged.
NOTE: If you use a new Crank Case Ass'y [61]<60>, unnecessary portion of the Crank Case
Packing [62]<61> must be cut off along the Cylinder Set PN [19]<19> matching surface
after assembling the Crank Case Ass'y [61]<60>.
(4) Reassembling the magneto rotor comp.
Mount the Magneto Rotor Comp. [136]<136> while aligning the integral key at the center hole of the
Magneto Rotor Comp. [136]<136> with the key groove in the Crank Shaft Ass'y [60]<59>.
(5) Reassembling the carburetor ass'y
When reassembling the Carburetor Ass'y [48]<48>, align the pulsed holes on the Carburetor Gasket
[47]<47> and Throttle Wire Fixing Plate [46]<46>, Carburetor Packing [45]<45>, Carburetor Insulator
Set PN [43]<43>, and Intake Packing [42]<42> with those on the Cylinder Set PN [19]<19> and
Carburetor Ass'y [48]<48>.
(6) Mounting the clutch drum comp.
While holding the inner ring of the ball bearing in the Fan Case [118]<118> so as not to damage two
4-mm cylindrical protrusions, press-fit the Clutch Drum Comp. [119]<119> and then attach the Stop
Ring C-12 Outer [117]<117>.
3. Mounting the loop handle ass'y
Position the Loop Handle Ass'y Anti-vib. [161]<161> as indicated by the Level Mark [169]<169> on the
Main Pipe Comp. [170]<170>, and then fasten the loop handle with Handle Bracket (A) [173]<173> by
evenly tightening the two Bolts 6 x 43/P (Black) [174]<174>.
Main Pipe Comp. [170] <170>
Handle Bracket (A) [173]<173>
Bolts 6 x 43/P (Black) [174]<174>
Exhaust mark (arrow)
Loop Handle Ass'y Anti-vib. [161]<161>
Level Mark [169]<169>
-13-
Piston Set
PN [55]<54>
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