Sakai RS45 Manual
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Sakai RS45 Manual

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RS45, RS55E, RS65, RS75
SHOP MANUAL
3498-64694-0

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Summary of Contents for Sakai RS45

  • Page 1 RS45, RS55E, RS65, RS75 SHOP MANUAL 3498-64694-0...
  • Page 3 Introduction This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI product. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit.

  • Page 5: Table Of Contents

    1-9. Stopping 1-004 1-10. Maintenance 1-004 1-11. Transporting the Machine 1-006 2. SPECIFICATIONS 1. SPECIFICATION DATA 2-001 1-1. RS45:Chassis number 10000-19999, 30000-39999 2-001 1-2. RS45:Chassis number 20000-29999 2-002 1-3. RS55E 2-003 1-4. RS65:Chassis number 10000-29999 2-004 1-5. RS65:Chassis number 30000-39999 2-005 1-6.
  • Page 6 RS45, RS55E, RS65E, RS75 1-6. Checking bolts in each section for their tightness 3-005 1-7. Replacement of fuel fi lter (Only application model) 3-005 2. BASIC TROUBLESHOOTING 3-006 4. PARTS CATALOGUE 1. GUIDE FOR USE OF PARTS CATALOGUE 4-001 2. RS45 4-002 2-1.
  • Page 7 RS45, RS55E, RS65E, RS75 4-3. CYLINDER ASSY 4-052 4-4. SHOE ASSY 4-054 4-5. TANK ASSY 4-056 4-6. LEVER ASSY 4-058 4-6-1. Lever assy (Chassis number : 10000-31602) 4-060 4-6-2. Lever assy (Chassis number : 31603-39999) 4-062 4-7. NAME PLATE 4-062 4-7-1.
  • Page 8 3. DISASSEMBLY AND REASSEMBLY OF RAMMING SYSTEM 5-008 3-1. Disassembly of Crank Case 5-009 3-2. Disassembly of Cylinder 5-010 3-3. Removal of Connecting Rod 5-012 3-4. Removal of Gear 5-012 3-5. Removal of Bellows and Outer cylinder 5-013 3-6. Removal of Adapter 5-014 3-7.

  • Page 9: Safety

    SAFETY...

  • Page 11: General Safety

    SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol. DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and CAUTION are displayed, become alert. Your safety or those around you may be involved. NOTICE is used to provide important information that is not hazard related.

  • Page 12: Qualifi Cations Of Operators And Maintenance Personnel

    SAFETY • The machine is designed specifi cally for tamping earth and sand, soil, gravel and asphalt. The manufacturer cannot be responsible or held liable for any damage resulting from other types of jobs. The risk for such use lies entirely with the user. •...

  • Page 13: Pre Start Inspection

    SAFETY • Observe all safety instructions and warnings attached to the machine. • Make sure all safety instructions and warnings on the machine are complete and perfectly legible. • Stop the machine immediately in the event of any malfunction. Report any malfunction immediately to the supervisor or other person of authority.

  • Page 14: Operating

    SAFETY 1-8. Operating • Always make sure that there are no obstructions or persons in your line of travel before starting the rammer in motion. • Use caution and be very observant when operating in close quarters and congested areas. •...
  • Page 15 Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. • Use only the specifi ed fl uids and lubricants. Substitute only products known to be equivalent from reputable manufacturers.

  • Page 16: Transporting The Machine

    SAFETY 1-11. Transporting the Machine • Always shutdown the engine when transporting the rammer. • Tighten the fuel tank cap securely and close the fuel cock to prevent fuel from spilling. • Drain fuel when transporting the rammer over long distances or bad roads. •...

  • Page 17: Specifications

    SPECIFICATIONS...

  • Page 19: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. RS45:Chassis number 10000-19999, 30000-39999 RS45-02001 Model SAKAI RS45 RAMMER Physical Machine Weight *1 49 kg (108 lbs.) Total Length 700 mm (27.6 in.) Total Width 370 mm (14.6 in.) Total Height 965 mm (38.0 in.) Size of Tamping Plate (L) X (W) 340 mm X 230 mm (13.4 in.

  • Page 20: Rs45:Chassis Number 20000-29999

    SPECIFICATIONS 1-2. RS45:Chassis number 20000-29999 RS45-02002 Model SAKAI RS45 RAMMER Physical Machine Weight *1 48 kg (106 lbs.) Total Length 675 mm (26.6 in.) Total Width 385 mm (15.2 in.) Total Height 1025 mm (40.4 in.) Size of Tamping Plate (L) X (W) 340 mm X 230 mm (13.4 in.

  • Page 21: Rs55E

    SPECIFICATIONS 1-3. RS55E RS55E-02004 Model SAKAI RS55E RAMMER Physical Machine Weight *1 55 kg (121 lbs.) Total Length 675 mm (26.6 in.) Total Width 385 mm (15.2 in.) Total Height 1020 mm (40.2 in.) Size of Tamping Plate (L) X (W) 340 mm X 260 mm (13.4 in.

  • Page 22: Rs65:Chassis Number 10000-29999

    SPECIFICATIONS 1-4. RS65:Chassis number 10000-29999 RS65-02005 Model SAKAI RS65 RAMMER Physical Machine Weight *1 71 kg (157 lbs.) Total Length 740 mm (29.1 in.) Total Width 390 mm (15.4 in.) Total Height 1040 mm (40.9 in.) Size of Tamping Plate (L) X (W) 340 mm X 280 mm (13.4 in.

  • Page 23: Rs65:Chassis Number 30000-39999

    SPECIFICATIONS 1-5. RS65:Chassis number 30000-39999 RS65-02007 Model SAKAI RS65 RAMMER Physical Machine Weight *1 74 kg (163 lbs.) Total Length 745 mm (29.3 in.) Total Width 415 mm (16.3 in.) Total Height 1040 mm (40.9 in.) Size of Tamping Plate (L) X (W) 340 mm X 280 mm (13.4 in.

  • Page 24: Rs75:Chassis Number 10000-29999

    SPECIFICATIONS 1-6. RS75:Chassis number 10000-29999 RS75-02008 Model SAKAI RS75 RAMMER Physical Machine Weight *1 80 kg (176 lbs.) Total Length 795 mm (31.3 in.) Total Width 415 mm (16.3 in.) Total Height 1040 mm (40.9 in.) Size of Tamping Plate (L) X (W) 340 mm X 280 mm (13.4 in.

  • Page 25: Rs75:Chassis Number 30000-39999

    SPECIFICATIONS 1-7. RS75:Chassis number 30000-39999 RS75-02011 Model SAKAI RS75 RAMMER Physical Machine Weight *1 76 kg (168 lbs.) Total Length 745 mm (29.3 in.) Total Width 415 mm (16.3 in.) Total Height 1040 mm (40.9 in.) Size of Tamping Plate (L) X (W) 340 mm X 280 mm (13.4 in.

  • Page 26: Rs75(Krf4):Chassis Number 80000-89999

    SPECIFICATIONS 1-8. RS75(KRF4):Chassis number 80000-89999 RS75-02009 Model SAKAI RS75(KRF4) RAMMER Physical Machine Weight *1 80 kg (176 lbs.) Total Length 795 mm (31.3 in.) Total Width 420 mm (16.5 in.) Total Height 1040 mm (40.9 in.) Size of Tamping Plate (L) X (W) 340 mm X 280 mm (13.4 in.

  • Page 27: Fuel And Lubricant

    SPECIFICATIONS 2. FUEL AND LUBRICANT 2-1. Fuel Fuel to be employed : Regular gasoline for automobile Fuel tank capacity : 2.2 L (0.58 gal.) 2-2. Engine oil/Vibrator oil Ambient temperature Season Viscosity rating Summer 25°C and above SAE#30 Spring/Autumn 10°C - 25°C SAE#20 or #30 Winter –10°C - 10°C...

  • Page 28: Tightening Torque Chart

    SPECIFICATIONS 3. TIGHTENING TORQUE CHART N·m (lbf·ft) Strength Classification Nominal Pitch Dia. 10.9 12.9 (3.6) (4.4) (5.8) (5.8) (5.8) (7.2) (9.6) (9.6) 1.25 (13) (17) (23) (23) (29) (36) (44) (44) 1.75 (51) (58) (80) (80) (72) (94) (123) (123) (116) (145) (195)

  • Page 29: Inspection And Maintenance

    INSPECTION AND MAINTENANCE...

  • Page 31: Engine

    Remove the spark plug to clean off carbon deposit on the plug every 50 hours of operation. Adjust electrode gap to between 0.6 mm and 0.7 mm. Spark plugs to be employed: Engine HONDA ROBIN Model RS45 CR4HSB(NGK) BMR4A(NGK) RS55E ————— RS65 CR5HSB(NGK) B6ES(NGK)

  • Page 32: Air Cleaner

    After cleaning, dip it in blended oil (mixture in the ratio of 1 for engine oil to 3 for kerosene) and squeeze it hard for reassembling. HONDA Engine: RS45, RS65 RS45-03002 HONDA Engine: RS45, RS65 RS45-03003 HONDA Engine: RS75...
  • Page 33 INSPECTION AND MAINTENANCE ROBIN Engine: RS45, RS55E, RS65, RS75 RS45-03005 ROBIN Engine: RS45, RS55E RS45-03006 ROBIN Engine: RS65, RS75 RS65-03007 3-003...
  • Page 34 INSPECTION AND MAINTENANCE HONDA Engine, RS75(KRF4) model: 1) Remove the wing nut from the air cleaner cover, and remove Wing nut the cover. Air cleaner cover 2) Remove the wing nut from the air fi lter, and remove the fi lter. 3) Remove the foam fi...

  • Page 35: Rammer Cylinder

    Position the tamping shoe to be level to supply oil until it will overfl ow out of the drain plug. Quantity specifi ed RS45-03009 Model Quantity specifi ed RS45, RS55E 500 cc RS65 800 cc RS75 900 cc 1-6. Checking bolts in each section for their tightness Check the mounting bolts for tightness.

  • Page 36: Basic Troubleshooting

    INSPECTION AND MAINTENANCE 2. BASIC TROUBLESHOOTING Refer to following basic troubleshooting table if product have some problems or failures. If the problem cannot be remedied, contact to Sakai authorized dealer or Sakai service department. Symptom Cause Action Engine will not start or No fuel in tank.

  • Page 37: Parts Catalogue

    PARTS CATALOGUE...

  • Page 39: Guide For Use Of Parts Catalogue

    PARTS CATALOGUE 1. GUIDE FOR USE OF PARTS CATALOGUE 1. Quote the following when placing an order for parts. (1) Vehicle model Model RS45 VRS4-00000 (2) Chassis number 5RS5-00000 RS55E RS65 VRS2-00000 (3) Part number RS75 VRS3-00000 (4) Part name Chassis number (5) Quantity of required parts.

  • Page 40: Rs45

    PARTS CATALOGUE 2. RS45 2-1. Frame 2-1-1. Frame (HONDA Engine, Chassis number : 10000-19999, 30000-39999) TANK ASSY LEVER ASSY No.10000-10314 CASE ASSY CYLINDER ASSY SHOE ASSY Illustration shows the chassis number 10315-19999. 4-002...
  • Page 41 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1472-12061-0  ボルト  BOLT  2  10000-10294,30000-39999      1  2100-08025-3  ボルト  BOLT  2  10295-19999       ...

  • Page 42: Frame (Robin Engine, Chassis Number : 20000-20700)

    PARTS CATALOGUE 2-1-2. Frame (ROBIN Engine, Chassis number : 20000-20700) TANK ASSY LEVER ASSY CASE ASSY CYLINDER ASSY SHOE ASSY 4-004...
  • Page 43 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2107-08020-3  ボルト  BOLT  4  20000-20510   1  2107-08025-3  ボルト  BOLT  4  20511-20700   2  2172-08012-1  コニカルワッシャ ...

  • Page 44: Frame (Robin Engine, Chassis Number : 20701-29999)

    PARTS CATALOGUE 2-1-3. Frame (ROBIN Engine, Chassis number : 20701-29999) TANK ASSY LEVER ASSY 23, 60 CASE ASSY CYLINDER ASSY SHOE ASSY 4-006...
  • Page 45 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2107-08025-3  ボルト  BOLT  4    2  2172-08012-1  コニカルワッシャ  CONICAL SPRING WASHER  4    3  2100-08016-1  ボルト  BOLT  4 ...
  • Page 46 PARTS CATALOGUE 2-2. CASE ASSY 4-008...

  • Page 47: Case

    PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1469-47002-0  ケース  CASE  1  10000-10294,20000-20770,             30000-39999   1  1469-47002-1  ケース ...

  • Page 48: Cylinder Assy

    PARTS CATALOGUE 2-3. CYLINDER ASSY 4-010...
  • Page 49 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1469-47016-0  ピン  PIN  1    2  1469-47003-0  シリンダ  CYLINDER  1    3  2630-01100-1  Ｏ−リング  O-RING  1 ...

  • Page 50: Shoe Assy

    PARTS CATALOGUE 2-4. SHOE ASSY 4-012...
  • Page 51 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1578-47516-0  ボルト  BOLT  2    2  2171-10025-0  スプリングワッシャ  SPRING WASHER  2    3  1579-47320-0  ナット  NUT  2 ...

  • Page 52: Tank Assy

    PARTS CATALOGUE 2-5. TANK ASSY Illustration shows the chassis number 10265-10294. 4-014...
  • Page 53 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4190-09006-5  キャップ  CAP  1  INC.14, 15 10000-10264,             20000-20510,30000-39999   1  4190-09006-6  キャップ ...

  • Page 54: Lever Assy

    PARTS CATALOGUE 2-6. LEVER ASSY 2-6-1. Lever assy (Chassis number : 10000-19999, 20000-20700, 30000-39999) 4-016...
  • Page 55 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1466-47033-0  ラック  RACK  1    2  2630-01045-1  O −リング  O-RING  2    3  1466-47032-0  ピニオン  PINION ...

  • Page 56: Lever Assy (Chassis Number : 20701-29999)

    PARTS CATALOGUE 2-6-2. Lever assy (Chassis number : 20701-29999) 4-018...
  • Page 57 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4911-98000-0  スイッチ  SWITCH  1    2  2633-00140-0  O −リング  O-RING  1    3  1466-47156-0  プランジャ  PLUNGER ...

  • Page 58: Name Plate

    PARTS CATALOGUE 2-7. NAME PLATE 2-7-1. Name plate (Chassis number : 10000-10264, 30000-39999) VIEW A VIEW B 4-020...
  • Page 59 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-19008-0  銘板  DECAL  1    2  1466-19005-0  銘板  DECAL  1  10000-10264   2  1570-19001-0  ステッカ  STICKER ...

  • Page 60: Name Plate (Chassis Number : 10265-19999)

    PARTS CATALOGUE 2-7-2. Name plate (Chassis number : 10265-19999) VIEW A VIEW B No.10315-19999 4-022...
  • Page 61 DECAL  1    2  1570-19001-0  銘板  DECAL  1    3  1462-19006-0  銘板  DECAL  1    5  1469-19006-0  銘板  DECAL  1  RS45   6  3998-36001-0  銘板  DECAL  1  DANGER   7  3998-06140-0  銘板  DECAL  1  NOTICE   8  1472-19018-0  銘板  DECAL ...

  • Page 62: Name Plate (Chassis Number : 20000-29999)

    PARTS CATALOGUE 2-7-3. Name plate (Chassis number : 20000-29999) VIEW A VIEW B 4-024...
  • Page 63 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4711-54000-0  銘板  DECAL  1  20000-20510   1  1467-19008-0  銘板  DECAL  1  20511-29999   2  4709-82000-0  銘板 ...

  • Page 64: Rs55E

    PARTS CATALOGUE 3. RS55E 3-1. Frame TANK ASSY LEVER ASSY CASE ASSY CYLINDER ASSY SHOE ASSY 4-026...
  • Page 65 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  0466-47015-0  タンク ASSY  TANK ASSY  1  10000-10223   1  0466-47015-1  タンク ASSY  TANK ASSY  1  10224-10663   1  0466-47018-0 ...

  • Page 66: Case Assy

    PARTS CATALOGUE 3-2. CASE ASSY 4-028...
  • Page 67 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1469-47002-0  ケース  CASE  1  10000-10183   1  1469-47002-1  ケース  CASE  1  10184-19999   2  1469-47066-0  カバー ...

  • Page 68: Cylinder Assy

    PARTS CATALOGUE 3-3. CYLINDER ASSY 4-030...
  • Page 69 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1469-47016-0  ピン  PIN  1    2  1469-47073-0  シリンダ  CYLINDER  1    3  2630-01100-1  Ｏ−リング  O-RING  1 ...

  • Page 70: Shoe Assy

    PARTS CATALOGUE 3-4. SHOE ASSY 4-032...
  • Page 71 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1578-47516-0  ボルト  BOLT  2    2  2171-10025-0  スプリングワッシャ  SPRING WASHER  2    3  1579-47320-0  ナット  NUT  2 ...

  • Page 72: Tank Assy

    PARTS CATALOGUE 3-5. TANK ASSY Illustration shows the chassis number 10000-10183. 4-034...
  • Page 73 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4190-09006-6  キャップ  CAP  1  INC.7 8 10000-10663   1  4190-09006-7  キャップ  CAP  1  INC.7 8 10664-19999   2  4709-99000-2  タンク ...

  • Page 74: Lever Assy

    PARTS CATALOGUE 3-6. LEVER ASSY 4-036...
  • Page 75 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4911-98000-0  スイッチ  SWITCH  1    2  2633-00140-0  O −リング  O-RING  1    3  1466-47156-0  プランジャ  PLUNGER ...

  • Page 76: Name Plate

    PARTS CATALOGUE 3-7. NAME PLATE VIEW A VIEW B 4-038...
  • Page 77 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1469-19011-0  デカール  DECAL  1  THROTTLE   2  1467-19008-0  デカール  DECAL  1    3  1570-19001-0  デカール  DECAL ...

  • Page 78: Rs65

    PARTS CATALOGUE 4. RS65 4-1. Frame (1) 4-1-1. Frame (1) (HONDA Engine, Chassis number : 10000-29999) LEVER ASSY TANK ASSY 28, 47 No.10981-19999 Illustration shows the chassis number 12917-19999. 4-040...
  • Page 79 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1466-47061-0  ガード  GUARD  1  10000-10980,20000-29999   1  1466-47061-1  ガード  GUARD  1  10981-19999   2  1472-12062-0  ボルト ...

  • Page 80: Frame (1) (Robin Engine, Chassis Number : 30000-31602)

    PARTS CATALOGUE 4-1-2. Frame (1) (ROBIN Engine, Chassis number : 30000-31602) LEVER ASSY TANK ASSY Illustration shows the chassis number 30740-30959. 4-042...
  • Page 81 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47006-0  プロテクタ  PROTECTER  1    2  2100-08020-1  ボルト  BOLT  4    3  2171-08020-0  スプリングワッシャ  SPRING WASHER  4 ...

  • Page 82: Frame (1) (Robin Engine, Chassis Number : 31603-39999)

    PARTS CATALOGUE 4-1-3. Frame (1) (ROBIN Engine, Chassis number : 31603-39999) TANK ASSY 4-044...
  • Page 83 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47006-0  プロテクタ  PROTECTER  1    2  2100-08020-1  ボルト  BOLT  4    3  2171-08020-0  スプリングワッシャ  SPRING WASHER  4 ...

  • Page 84: Frame

    PARTS CATALOGUE 4-2. FRAME (2) 4-2-1. Frame (2) (HONDA Engine, Chassis number : 10000-29999) No.12917-19999 No.12917-19999 CYLINDER ASSY SHOE ASSY Illustration shows the chassis number 12032-12390. 4-046...
  • Page 85 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING  2    2  2194-03015-0  スナップリング  RETAINING RING  1    3  1468-47007-0  ピニオン  PINION  1 ...

  • Page 86: Frame (2) (Robin Engine, Chassis Number : 30000-31602)

    PARTS CATALOGUE 4-2-2. Frame (2) (ROBIN Engine, Chassis number : 30000-31602) 14, 42 CYLINDER ASSY SHOE ASSY Illustration shows the chassis number 30740-30959. 4-048...
  • Page 87 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING  2    2  2194-03015-0  スナップリング  RETAINING RING  1    3  1468-47007-0  ピニオン  PINION  1 ...

  • Page 88: Frame (2) (Robin Engine, Chassis Number : 31603-39999)

    PARTS CATALOGUE 4-2-3. Frame (2) (ROBIN Engine, Chassis number : 31603-39999) LEVER ASSY CYLINDER ASSY SHOE ASSY 4-050...
  • Page 89 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING  2    2  2194-03015-0  スナップリング  RETAINING RING  1    3  1468-47007-0  ピニオン  PINION  1 ...

  • Page 90: Cylinder Assy

    PARTS CATALOGUE 4-3. CYLINDER ASSY No.10000-10261 No.30000-30290 No.10262-29999 No.30291-39999 4-052...
  • Page 91 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1466-47099-0  シリンダ  CYLINDER  1  10000-19999,20000-29999   1  1466-47024-0  シリンダ  CYLINDER  1  30000-30290   1  1466-47099-1  シリンダ ...

  • Page 92: Shoe Assy

    PARTS CATALOGUE 4-4. SHOE ASSY 4-054...
  • Page 93 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47008-0  プレート  PLATE  1  A/S(CF.8)   2  1467-47009-0  シュー  SHOE  1  A/S(CF.8)   3  3120-41008-0  アイナット ...

  • Page 94: Tank Assy

    PARTS CATALOGUE 4-5. TANK ASSY Illustration shows the chassis number 12573-12866. 4-056...
  • Page 95 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4190-09006-4  キャップ  CAP  1  INC.15,16 10000-10260,             30261-30290   1  4190-09006-5  キャップ ...

  • Page 96: Lever Assy

    PARTS CATALOGUE 4-6. LEVER ASSY 4-6-1. Lever assy (Chassis number : 10000-31602) 4-058...
  • Page 97 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1466-47033-0  ラック  RACK  1    2  2630-01045-1  O −リング  O-RING  2    3  1466-47032-0  ピニオン  PINION ...

  • Page 98: Lever Assy (Chassis Number : 31603-39999)

    PARTS CATALOGUE 4-6-2. Lever assy (Chassis number : 31603-39999) 4-060...
  • Page 99 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4911-98000-0  スイッチ  SWITCH  1    2  2633-00140-0  O −リング  O-RING  1    3  1466-47156-0  プランジャ  PLUNGER ...

  • Page 100: Name Plate

    PARTS CATALOGUE 4-7. NAME PLATE 4-7-1. Name plate (Chassis number : 10000-12572) VIEW A VIEW B 4-062...
  • Page 101 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1570-19001-0  銘  板  DECAL  1    2  1467-19008-0  銘  板  DECAL  1    3  1462-19006-0  銘  板  DECAL  1 ...

  • Page 102: Name Plate (Chassis Number : 12573-19999, 20000-29999)

    PARTS CATALOGUE 4-7-2. Name plate (Chassis number : 12573-19999, 20000-29999) VIEW A VIEW B 4-064...
  • Page 103 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1570-19001-0  銘  板  DECAL  1    2  1467-19008-0  銘  板  DECAL  1    3  1462-19006-0  銘  板  DECAL  1 ...

  • Page 104: Name Plate (Chassis Number : 30000-31602)

    PARTS CATALOGUE 4-7-3. Name plate (Chassis number : 30000-31602) VIEW A 4-066...
  • Page 105 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  3998-06140-0  銘  板  DECAL    2  2998-10006-6  銘  板  DECAL    3  2998-11001-6  銘  板  DECAL    4  1467-19003-0 ...

  • Page 106: Name Plate (Chassis Number : 31603-39999)

    PARTS CATALOGUE 4-7-4. Name plate (Chassis number : 31603-39999) VIEW A VIEW B 4-068...
  • Page 107 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  3998-36001-0  銘  板  DECAL    2  3998-06140-0  銘  板  DECAL    3  1472-19018-0  銘  板  DECAL    4  1467-19003-0 ...

  • Page 108: Rs75

    PARTS CATALOGUE 5. RS75 5-1. Frame (1) 5-1-1. Frame (1) (HONDA Engine, Chassis number : 10000-29999, 80000-89999) LEVER ASSY TANK ASSY No.10199-19999 No.80000-89999 No.10000-10198 No.20101-29999 Illustration shows the chassis number 10000-10102. 4-070...
  • Page 109 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1468-47026-0  ガード  GUARD  1  10000-10198,20000-29999   1  1468-47026-1  ガード  GUARD  1  10199-19999,80000-89999   2  2107-08025-3  ボルト ...

  • Page 110: Frame (1) (Robin Engine, Chassis Number : 30000-30782)

    PARTS CATALOGUE 5-1-2. Frame (1) (ROBIN Engine, Chassis number : 30000-30782) LEVER ASSY TANK ASSY 4-072...
  • Page 111 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47006-0  プロテクタ  PROTECTOR  1    2  2100-08020-1  ボルト  BOLT  4    3  2171-08020-0  スプリングワッシャ  SPRING WASHER  4 ...

  • Page 112: Frame (1) (Robin Engine, Chassis Number : 30783-39999)

    PARTS CATALOGUE 5-1-3. Frame (1) (ROBIN Engine, Chassis number : 30783-39999) TANK ASSY 4-074...
  • Page 113 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47006-0  プロテクタ  PROTECTER  1    2  2100-08020-1  ボルト  BOLT  4    3  2171-08020-0  スプリングワッシャ  SPRING WASHER  4 ...

  • Page 114: Frame

    PARTS CATALOGUE 5-2. Frame (2) 5-2-1. Frame (2) (HONDA Engine, Chassis number : 10000-29999, 80000-89999) No.80000-89000 CYLINDER ASSY SHOE ASSY Illustration shows the chassis number 10289-10379. 4-076...
  • Page 115 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING  2    2  2194-03015-0  スナップリング  RETAINING RING  1    3  1468-47007-0  ピニオン  PINION  1 ...

  • Page 116: Frame (2) (Robin Engine, Chassis Number : 30000-30782)

    PARTS CATALOGUE 5-2-2. Frame (2) (ROBIN Engine, Chassis number : 30000-30782) CYLINDER ASSY SHOE ASSY 4-078...
  • Page 117 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING    2  2194-03015-0  スナップリング  RETAINING RING    3  1468-47007-0  ピニオン  PINION    4  1466-47034-0 ...

  • Page 118: Frame (2) (Robin Engine, Chassis Number : 30783-39999)

    PARTS CATALOGUE 5-2-3. Frame (2) (ROBIN Engine, Chassis number : 30783-39999) LEVER ASSY CYLINDER ASSY SHOE ASSY 4-080...
  • Page 119 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  2501-06206-0  ボールベアリング  BALL BEARING  2    2  2194-03015-0  スナップリング  RETAINING RING  1    3  1468-47007-0  ピニオン  PINION  1 ...

  • Page 120: Cylinder Assy

    PARTS CATALOGUE 5-3. CYLINDER ASSY No.10000-10150 No.30000-30190 No.10151-29999 No.30191-39999 No.80000-89999 4-082...
  • Page 121 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1468-47032-0  シリンダ  CYLINDER  1  10000-19999,20000-29999,             30171-39999,80000-89999   1  1468-47014-0  シリンダ ...

  • Page 122: Shoe Assy

    PARTS CATALOGUE 5-4. SHOE ASSY 4-084...
  • Page 123 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1467-47008-0  プレート  PLATE  1  A/S(CF.8)   2  1467-47009-0  シュー  SHOE  1  A/S(CF.8)   3  3120-41008-0  アイナット ...

  • Page 124: Tank Assy

    PARTS CATALOGUE 5-5. TANK ASSY Illustration shows the chassis number 10469-19999. 4-086...
  • Page 125 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4190-09006-4  キャップ  CAP  1  INC.15,16  10000-10150,             30171-30210   1  4190-09006-5  キャップ ...

  • Page 126: Lever Assy

    PARTS CATALOGUE 5-6. LEVER ASSY 5-6-1. Lever assy (Chassis number : 10000-30782, 80000-89999) 4-088...
  • Page 127 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1466-47033-0  ラック  RACK  1    2  2630-01045-1  O −リング  O-RING  2    3  1466-47032-0  ピニオン  PINION ...

  • Page 128: Lever Assy (Chassis Number : 30783-39999)

    PARTS CATALOGUE 5-6-2. Lever assy (Chassis number : 30783-39999) 4-090...
  • Page 129 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  4911-98000-0  スイッチ  SWITCH  1    2  2633-00140-0  O −リング  O-RING  1    3  1466-47156-0  プランジャ  PLUNGER ...

  • Page 130: Name Plate

    PARTS CATALOGUE 5-7. NAME PLATE 5-7-1. Name plate (Chassis number : 10000-29999, 80000-89999) VIEW A VIEW B 4-092...
  • Page 131 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  1570-19001-0  銘  板  DECAL  1  10000-10468,80000-80191   2  1467-19008-0  銘  板  DECAL  1    3  1462-19006-0  銘  板  DECAL ...

  • Page 132: Name Plate (Chassis Number : 30000-30782)

    PARTS CATALOGUE 5-7-2. Name plate (Chassis number : 30000-30782) VIEW A 4-094...
  • Page 133 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  3998-06140-0  銘  板 :  DECAL  1    2  2998-10006-6  銘  板 :  DECAL  1    3  2998-11001-6  銘  板...

  • Page 134: Name Plate (Chassis Number : 30783-39999)

    PARTS CATALOGUE 5-7-3. Name plate (Chassis number : 30783-39999) VIEW A VIEW B 4-096...
  • Page 135 PARTS CATALOGUE 記 号 部 品 番 号 数量 備 考 Parts Name 部 品 名 称 Key No. Parts No. Q’ty Remarks   1  3998-36001-0  デカール  DECAL:DANGER  1    2  3998-06140-0  デカール  DECAL:NOTICE  1    3  1472-19018-0  デカール  DECAL:WARNING  1 ...

  • Page 137: Ramming System

    RAMMING SYSTEM...

  • Page 139: Precautions For Disassembly And Reassrmbly

    RAMMING SYSTEM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY WARNING • Do not remove the adapter without first reading disassembly procedures or taking instruction from someone familiar with its safe removal. The adapter is under heavy spring pressure and could cause a serious injury if the proper disassembly procedures are not followed.

  • Page 140: Removal And Installation Of Ramming System

    RAMMING SYSTEM 2. REMOVAL AND INSTALLATION OF RAMMING SYSTEM 2-1. Removal of Ramming System (Combined throttle lever and fuel valve type) • Illustration shows RS45, ROBIN engine, chassis number : 20701-29999. There is a part where the composition parts are different according to the model and chassis number.
  • Page 141 RAMMING SYSTEM Part name and number in order of its removal Q’ty Remarks WARNING Gasoline is highly fl ammable and its vapors may explode. Pay attention to following items when working with gasoline. • Work away from areas having sparks, fl ames or other sources of heat.

  • Page 142: Removal Of Ramming System (Separated Throttle Lever And Fuel Valve Type )

    RAMMING SYSTEM 2-2. Removal of Ramming System (Separated throttle lever and fuel valve type ) OPEN • Illustration shows RS65, HONDA engine, chassis number : 12032-12390. There is a part where the composition parts are different according to the model and chassis number. Refer to the corresponding model and chassis number illustrations in the parts catalogue chapter.
  • Page 143 RAMMING SYSTEM Part name and number in order of its removal Q’ty Remarks WARNING Gasoline is highly fl ammable and its vapors may explode. Pay attention to following items when working with gasoline. • Work away from areas having sparks, fl ames or other sources of heat.

  • Page 144: Removal Of Centrifugal Clutch

    1) Remove the nut (18) and clutch plate from the centrifugal clutch (20). Clutch plate RS45-05003 2) Remove the centrifugal clutch (20) with the clutch pullers. CAU T IO N Be careful not to damage the thread grooves on the shaft.

  • Page 145: Installation Of Ramming System

    • If using M10 nuts for engine mounting, tighten them with the torque shown below. • After installation, adjust the engine speed to the values in the chart below. Model name Idle Full throttle RS45, RS65 Honda engine GX100* 1800±150 min 3600 min RS75 Honda engine GX120* 1500±100 min...

  • Page 146: Disassembly And Reassembly Of Ramming System

    RAMMING SYSTEM 3. DISASSEMBLY AND REASSEMBLY OF RAMMING SYSTEM 3-1. Disassembly of Crank Case • Illustration shows RS65, HONDA engine, chassis number : 12032-12390. There is a part where the composition parts are different according to the model and chassis number. Refer to the corresponding model and chassis number illustrations in the parts catalogue chapter.
  • Page 147 RAMMING SYSTEM Remarks Part name and number in order of its removal Q’ty Remove the two M10x40 bolts (16). Remove the pin (9) and then, remove the crank case assembly (4) 4 : Crank case from the cylinder assembly (11). Remove the ten M6x16 bolts (1) and cover (2).

  • Page 148: Disassembly Of Cylinder

    RAMMING SYSTEM 3-2. Disassembly of Cylinder • Illustration shows RS65, HONDA engine, chassis number : 12032-12390. There is a part where the composition parts are different according to the model and chassis number. Refer to the corresponding model and chassis number illustrations in the parts catalogue chapter.
  • Page 149 RAMMING SYSTEM Remarks Part name and number in order of its removal Q’ty Remove the two M8 nuts (3). Then remove the upper and lower clamps (6). 7 : Bellows Remove the upper and lower locking pads (2). Remove the bellows (7) and outer cylinder (1). Refer to 3-5. Removal of Bellows and Outer Cylinder.

  • Page 150: Removal Of Connecting Rod

    5-008. 1) Remove the bearing and connecting rod (7) with the puller. RS45-05007 3-4. Removal of Gear 1) Remove the C-retaining ring (3) holding the pinion (10) in place.

  • Page 151: Removal Of Bellows And Outer Cylinder

    RAMMING SYSTEM 3) Remove the C-retaining ring (5) holding the gear (6) in place and then remove the gear. RS45-05010 3-5. Removal of Bellows and Outer cylinder • The lead line numbers shown in the illustration below are consistent with the part numbers of the cylinder shown on pages 5-010.

  • Page 152: Removal Of Adapter

    After ensuring that the M10x40 bolts are removed, install the jig. • When removing the adapter for the RS45 and RS55E, just substitute the M10×40 and M10 × 20 bolts with the M8×35 and M8x16 bolts shown in the manual.

  • Page 153: Removal Of Slider

    1) Attach a pin or similar device in the piston (8) so that it cannot move. Then place it in a vise, etc. • Remove the M18 nut (14). RS45-05015 2) Remove the slider (13) with the jig. Jig Number : 9469-47001-0 (For RS45, RS55E) 9466-47001-0 (For RS65, RS75) RS45-05016 5-015...

  • Page 154: Reassembly Of Crank Case/Cylinder

    Reaasemble the crank case and cylinder in the reverse order in which it was disassembled. (NOTICE) • When installing the slider (13), apply thread-locking fl uid on the tap portion. RS45, RS55E only (Page 5-010) • When installing the M8 nut (14), apply thread-locking fl uid on the threaded portion. RS65, RS75 only (Page 5-010) •...
  • Page 156 SAKAI HEAVY INDUSTRIES, LTD. Head offi ce: Seiwa Bldg., 4-8, Shibadaimon 1-chome, Minato-ku, Tokyo, Japan Telephone: +81-3-3434-3401 Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan Telephone: +81-480-52-1111 Copy right © 2011 SAKAI HEAVY INDUSTRIES, LTD. All Right Reserved. Printed in Japan 2013.1.0...

This manual is also suitable for:

Rs55eRs65Rs75

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