EY35, EY40 - Small Engine Discount

5-4 HOW TO REASSEMBLE
5-4-1 PRECAUTION IN REASSEMBLY
Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the cleanliness of the
piston, cylinder, crankshaft, connecting rod and bearings.
Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adhered
in the groove of the piston ring should be carefully and completely taken out.
Carefully check the lip portion of every oil seal. If faulty one is found, replace it without any hesitation.
Apply enough oil to the lip portion of the oil seal when reassembling.
Replace all the gaskets with new ones.
Replace the key, pin, bolt, nuts, etc. with new one, if necessary.
Whenever tightening torque is specified, conform to the specified figures.
Apply oil to the revolutionary parts and friction surfaces, when reassembling.
Check and adjust the clearances of various portions and then reassemble.
When some main portions are assembled in the course of reassembling, turn or move the gadgets by hand and pay at-
tention to the frictional noise and resistance.
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5-4-2 MEASURING CRANKCASE and CRANKSHAFT
Bore the cylinder or take other steps as necessary to meet
the following specifications before reassembling.
EY35
E Y40
29 +0.1
I W (Crankshaft Pin Width) I 0
Bore
Piston Outside Diameter (In Skirt Thrust Direction)
78 dia.
40.019
I
84 dia. , +0.022
I Piston to Cylinder at Piston Skirt Thrust Face I
0.049L - 0.1 08L 1 0.049L - 0.1 11 L
Piston Ring Gap (Top Ring - Second Ring)
Piston Ring Side Clearance in Grooves
(Top Ring - Second Ring)
I
0.1 L - 0.3L
0.05 - 0.09
Clearance between Connecting
Rod Large End and Piston Pin
Clearance between Connection
Rod Small End and Piston Pin
Clearance between Inside
and Outside Diameter
Side Clearance
0.070 - 0.102L
0.020L - 0.042L
0.1 L - 0.4L
Clearance between Piston Pin and Pinston Pin Hole
0.1 1T - 0.01 1 L
Fig. 27
L: LOOSE
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