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8.
DISMANTLING MOTOR - MASTER 35®
1. REPLACE AIR FILTER 4003.0451
Unfasten two Screws 0180 on Filter Cover 0990
and lift off. Remove and replace Air Filter.
2. REMOVING TOP COVER 2870.1100
Loosen three screws 0480. Push rubber air intake
0770 through Top Cover. Remove wires from Start/Stop
Switch 0491 noting position for re-connecting.
Refit using Air Intake Tool Part No. 4002 9005.
3.
REPLACING PRIMER ASSEMBLY 4003.0810
Remove screws 2303.0315 and take off Bulb Protector
2650.1010 and pull Primer from Motor.
Please note: for Primer re-connection connect
Pipe 1190 from Fuel Tank to "out" port
and Pipe 0910 from the Carburettor. "in"
port.
4. REPLACING STARTER RECOIL SPRING 4003.04501
Follow procedure for replacing Pull Cord.
With the Pulley separated from Starter Housing,
remove the two Screws.
Remove old Spring Cassette and replace with new
one. Refit Screws.
When refitting Starter Housing pull Starter Cord
to ensure it operates before tightening Screws.
5. REMOVING FLYWHEEL 4003.1186
Fit Piston Stop Tool 4000.0020 into Cylinder and
remove Flywheel Nut 0040. Remove Flywheel Ratchet
Assembly 1187. Using Puller 10.00049 with Screws
10.00362 remove Flywheel. Take care not to lose
Key 0220.
6. REMOVING EXHAUST GUARD 8 AND MUFFLER ASSEMBLY
4003.0850
Remove five Screws 7 holding Exhaust Guard and
lift off. Unfasten two Screws 0640 on inside of
Exhaust Box and remove it and Gasket 0860 from
Motor.
Ensure Motor/Muffler is warm when re-fitting screws.
7. REMOVING THE CARBURETTOR 4003.0510
Remove two Screws 0080, Screw 0720 and Fuel Pipes
0190 & 0920 from Carburettor making sure to
note re-connecting positions. Disconnect Choke
Linkage 0880 and Throttle Linkage 1020 and remove
Carburettor.
8. DISMANTLING MOTOR FROM IMPACT UNIT
Remove Carrying Handle 97 and four Screws 24 holding
Clutch Support Flange 18 to Motor Flange 9. Pull
apart.
9. REMOVING CYLINDER AND PISTON 4003.1165
Remove three Screws 0410 holding Carburettor Flange
0740 to Casing. Depress Spring Clip 0390 behind
Carburettor Flange and pull from Cylinder. Loosen
four Screws 0630 holding down Cylinder and lift
off. Remove Spring Clip 4001.4200 from inside
Piston and Gudgeon Pin 0800. Lift off Piston 1120.
Check Piston Rings 0820 for wear and replace if
necessary. Rebuild in reverse order.
Please Note: If Clutch is to be removed leave
Cylinder and Piston in position until after this
is done.
10.REMOVING CRANKCASE 4003.1150 & 4003.1169
FROM FUEL TANK 4003.1045
Remove Screws 0110 to allow Crankcase to be disconnected
from Fuel Tank.
11. REMOVING CRANKSHAFT 4003.0985
Remove seven Screws from Clutch side of Crankcase.
Run Flywheel Nut 0040 onto Crankshaft 0985 until
flush with the end. Hold Crankcase tightly and
using a soft faced mallet tap against the Flywheel
Nut until the casing splits.
PLEASE NOTE:
a) It is advisable to replace all Gaskets and
Seals when rebuilding Motor.
b) If Primer Bulb 0810 is burst disconnect two
Fuel Pipes 0910 and 1190 and plug the holes.
DO NOT CONNECT THE PIPES TOGETHER
Replace Primer Bulb Assembly as soon as possible
- see section 8.3 on previous page.
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