Disassembly And Reassembly; Disassembling The Engine - Hitachi CS 27EPAP(S) Service Manual

Do not reuse the following parts.
• Cover Packing [13]<13>
• Intake Packing [42]<42>
• Seal Lock Hex. Socket Hd. Bolt M5 x 30 [9]<9>
• Hex. Hole Bolt 5 x 20S [11]<11>
• Hex. Hole Bolt 4 x 12WS [15]<15>
• Seal Lock Hex. Socket Bolt (W/Washers) M5 [44]<44>
• Hex. Hole Bolt 4 x 18WS [127]<127>
• Chain Bar Knock Pin [224]<224>

1. Disassembling the engine

(1) Separating the engine from the main pipe
Loosen the Hex. Hole Bolt M5 x 12S [111]<111> and two Hex. Hole Bolts M5 x 25S [112]<112>, and
then separate the engine from the Main Pipe Comp. [170]<170>.
(2) Removing the muffler
Loosen the two Screws 5 x 16/PS [5]<5> and then remove the Muffler Cover [4]<4>. Loosen the two
Hex. Hole Bolts 6 x 65 [6] or Hex. Hole Bolts M6 x 55 <6>, and then remove the Muffler (B) [8] or
Muffler <8> and the Heat Protection Panel [10]<10> together.
(3) Removing the cylinder cover and the spark plug
Loosen the two Seal Lock Hex. Socket Hd. Bolts M5 x 30 [9]<9> and two Screws 4 x 22/PS [3]<3>,
and then remove the Cylinder Cover [1]<1>. Next, remove the plug cap from the Spark Plug [12]<12>
and then remove the Spark Plug [12]<12>.
(4) Removing the tank
Loosen the two Flange Bolts [145]<145> and the Bolt (W/Flange) L27.8 [148]<148>.
Pull out the pipe of the Shield Tube 3 x 5 x 180 [137]<137> and the Fuel Pipe 3 x 5 x 85 [138]<138>
from the Carburetor Ass'y [48]<48>. Then remove the Tank [143]<143>.
(5) Removing the air filter ass'y, carburetor ass'y, and carburetor insulator set
Open the Air Cleaner Cap [53]<52> of the Air Filter Ass'y [54]<53>, loosen the two Plus Screws 5 x
60WS [50]<50>, and then remove the Air Filter Ass'y [54]<53>, Carburetor Ass'y [48]<48>, Carburetor
Gasket [47]<47>, Throttle Wire Fixing Plate [46]<46>, and Carburetor Packing [45]<45> together.
Loosen the two Seal Lock Hex. Socket Bolts (W/Washers) M5 [44]<44>, and then remove the
Carburetor Insulator Set PN [43]<43> and the Intake Packing [42]<42> together.
(6) Removing the recoil starter body ass'y
Loosen the two Screws 4 x 22/PS [3]<3>, and then remove the Recoil Starter Body Ass'y [71]<70>.
(7) Removing the fan case and clutch drum comp.
Remove the two Screws 4 x 22/PS [3]<3> and three Seal Lock Hex. Socket Hd. Bolts M5 x 30 [9]<9>.
Place the Fan Case [118]<118> so that its surface facing the crank case is positioned downward, while
being careful not to damage the two 4-mm cylindrical protrusions, and then remove the Stop Ring C-12
Outer [117]<117>. After that, use a hand press or other tool to slowly push the shaft of the Clutch Drum
Comp. [119]<119> and remove it without damaging the ball bearing of the Fan Case [118]<118>.
(8) Removing the ignition coil ass'y
Loosen the two Hex. Hole Bolts 4 x 18WS [127]<127> and then remove the Ignition Coil Ass'y
[128]<128>.
(9) Removing the clutch set and starter pulley ass'y
First, to lock the Crank Shaft Ass'y [60]<59>, insert the wire rope of the recoil starter or other part into
the Spark Plug [12]<12> mounting hole on the Cylinder Set PN [19]<19>, and then turn the Magneto
Rotor Comp. [136]<136> counterclockwise until the Piston Set PN [55]<54> is locked at the top dead

Disassembly and reassembly

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