Revised Troubleshooting Procedure for BL9000 Restart Failure

1. Main Reassembly Parts

* Ratchet parts shall be assembled onto the replacement rotor in advance. E-rings must not be reused.

2. Reassembly Procedure (1) Removing the top cover

❢Caution❢ Put all parts, screws and bolts to be reused in a box to make sure that they are not lost or mixed with other parts.

[1] Remove the top cover. Remove the five tapping screws using a Phillips screwdriver.

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(2) Removing the recoil [1] Remove the two leads that are pushed into the left of the recoil. [2] Unscrew the three hex socket head cap bolts to remove the recoil.

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Part number Item name Part number Item name

276032 Rotor 279232 Rotor

276465 Ignition coil assembly 279233 Ignition coil assembly

285549 Grommet 279721 Grommet

281864 Lead 279193 Lead

279194 Lead

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The leads are pushed in here.

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(3) Removing the ignition coil [1] Before removing the coil, disengage the clamp, and pull out the lead connecting part. [2] Remove the plug cap and the two grommets. Put the grommets in the parts box. [3] While making sure not to lose the two spacers that are inserted under the coil, unscrew the two

hex socket head cap bolts to remove the coil. Be sure to put the clamp, two spacers, and two bolts in the parts box. Be careful so as to avoid losing parts.

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[1] [2]

[2] [3]

Location of the lead connecting part

Grommet

(4) Removing the rotor [1] Remove the nut. [2] Set the dedicated tool in the gaps of the fin, and take the rotor out of the shaft.

Be careful when performing this step as the woodruff key may fall out. Remove the woodruff key from the shaft and put it in the parts box.

❢Caution❢ Make sure not to lose the woodruff key. If lost, do not proceed to the next process until found.

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Disassembly is now complete.

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Woodruff key

The assembly procedure is as follows. (5) Assembling the rotor

[1] Insert the woodruff key into the shaft. [2] While being careful to prevent the woodruff key from falling out, align the rotor groove and

assemble the rotor onto the shaft.

❢Caution❢ The woodruff key may fall out. Visually make sure that the woodruff key is not falling out while assembling the rotor.

[3] Tighten the nut. [Tightening torque 900 to 1300 N・cm]

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(6) Assembling the coil [1] Assemble the lead with a flag terminal onto the coil. Pay attention to the direction. Push it in all

the way. [2] Rotate the rotor so that the rotor magnet is on the coil side. [3] Place one spacer on each coil boss. [4] Set the coil so that a 0.4-mm gap sheet (blue) is positioned between the coil and the rotor

magnet. Be careful when performing this step as the spacers may fall out. Refer to the photo for the wiring of the lead.

[5] Jointly fasten the clamp onto the lower-left bolt and the lead with a round terminal onto the upper-right bolt. Refer to the photo for the directions of the clamp and the terminal. Remove the gap sheet once these parts are fastened.

[Tightening torque 250 to 380 N・cm] [6] Attach the plug cap, and then put a grommet (small) through the high-voltage cable.

Refer to the photo for the wiring of the plug cable and the cap direction. [7] Fit the grommet into the groove of the crank case.

Insert it so that the notch of the grommet is facing the back. [8] Secure the high-voltage cable with a clamp.

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[1] [3]

Spacer

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(7) Assembling the recoil [1] Assemble the recoil while slightly pulling the recoil rope, and tighten the three hex socket head

cap bolts. [Tightening torque 400 to 600 N・cm]

[2] Push in each of the two leads into the recoil groove, and secure each in place.

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[6] [7]

Grommet, clamp

Plug cap attachment directionGrommet insertion direction

(groove facing toward the back)

[4] [4]

Lead wiring

[8]

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(8) Lead connection and wiring [1] Connect the two leads. Either terminal can be used. Be careful not to let the sleeve become

turned up. Be sure to insert the bullet terminal all the way in.

[2] Once the leads are connected, secure them in place with the throttle wire using a clamp. [3] Wire the leads so that they are positioned on the inner side of the gasket below the cab.

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(9) Assembling the top cover [1] Assemble the top cover. It is best to insert it from the top side into the underside of the cleaner

cover. [2] Securely fit the groove of the upper-left grommet. Make sure there is no turning up. [3] Make sure that the corrugate tube of the throttle wire is securely fit in the groove. [4] Tighten the five tapping screws. Hand-tightening is recommended. Align the threads of the

screws. Do not tighten excessively. [5] Put a grommet (large) through the high-voltage cable, and put in into the groove. Pay attention

to the front and back directions.

❢Caution❢ Before tightening the tapping screws, first turn the screws to the left to align the threads. When the threads are aligned, there should be a clicking sensation.

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Push it into the groove.

[2][1]

Be careful not to let the sleeve become turned up. Inner side of the gasket (right side of the photo)

[1]/[2] [3]

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(10) Operating inspection [1] Perform an operating inspection to check whether there is no problem with each part.

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[2] [3]

[4] [5]

Be careful not to let the grommet become turned up.

Pay attention to the front and back