BBX7600 PARTS BREAKDOWN BBX7600CA PARTS BREAKDOWN · PDF filePARTS BREAKDOWN EM4251 ... modi˜ed. modi˜ed changed added ... CRANKSHAFT COMP., BBX7600. 1. 93. 597-20020-01. CRANKSHAFT

PARTS BREAKDOWN EM4251

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2

34

56

7

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9

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3233

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188

PARTS BREAKDOWNBBX7600

BBX7600CArev 11_12/28/2012

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190

191

192

Implemented Jan 2011

Insulation labels

Slits are filled with1mm thickness of the Insulation labels.

Their labels must be attached to the reverse of Engine cover.

Exhaust air outlet is modified.

Slits are eliminated.

Prior to Jan 2011

3030

24

23

25

26

2728

29

NOTE: Fig No’s 190, 191, 192not included with Fig No. 30.


BBX7600CArev 11_12/28/2012

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46

47

4849

50

5152

53

54

55

56

57

58

59


BBX7600CArev 11_12/28/2012

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61

62

63

64

65

66

6768

69

70

71

72

7374

75

76

77

78

79

818082

83


BBX7600CArev 11_12/28/2012

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84

85

86

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88

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90

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92


BBX7600CArev 11_12/28/2012

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9495

96

97

98

99

100

101

102

187

103

104

The groove is modi�ed.

modi�edchanged

added

The groove is modi�ed.94

9495

95

96 96

19897 97

Old New (Implemented March 2012)

Ref bulletin Y06029

The following parts have changed. (Interchangeable as a set)

Reference Service Note SN2012_13 on how to install.


BBX7600CArev 11_12/28/2012

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105

106

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108

109

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111

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115

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117


BBX7600CArev 11_12/28/2012

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128

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133 134

135

136

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140 141

142

143

144


BBX7600CArev 11_12/28/2012

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145

146

147

148

149

150

151152

153

154

155

156

157

158

159

160

161162

163

164165

166

167


BBX7600CArev 11_12/28/2012

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BBX7600CArev 11_12/28/2012

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186


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Tech Bulletins Fig. No. Part No. Description Q'ty Unit Notes1 667-10070-01 VOLUTE CASE 1 ASS'Y, BBX7600 12 667-10050-10 SQUARE NUT, BBX7600 23 014-00592-20 SCREW ASSY M5X65, BBX7600 24 667-10020-00 DAMPER 1 COMP., BBX7600 15 020-00599-10 WASHER M5, BBX7600 16 004-31054-00 P.H. SCREW M5X65 (W.SW), BBX7600 17 015-00597-30 TAPPING SCREW 5X25, BBX7600 38 667-10010-00 INLET COVER COMP., BBX7600 19 265878-0 TAPPING SCREW BIT 5X16 9

9 015-00598-00 TAPING SCREW M5X18, BBX7600 99 015-00597-60 T. SCREW 5X16, BHX2500 9

10 667-10030-00 DAMPER 2 COMPL., BBX7600 211 011-90696-90 S.H. BOLT M6X40, BBX7600 412 240138-1 IMPELLER, BBX7600 1

12 667-10040-00 IMPELLER COMPL., BBX7600 113 056-33799-90 WIRE BAND, BBX7600 114 667-15004-00 ELBOW, BBX7600 115 024-09899-90 O RING, BBX7600 116 266649-8 S.H. BOLT M6X30, BBX7600 6

16 011-90696-80 S.H. BOLT M6X30, BBX7600 617 667-15002-00 BASE 1, BBX7600 118 667-15003-00 BASE 2, BBX7600 119 667-10080-01 VOLUTE CASE 2 ASS'Y, BBX7600 120 667-10050-10 SQUARE NUT, BBX7600 221 017-00599-50 NUT M5, BBX7600 222 073-62899-80 CAUTION LABEL, BHX2500 1

Y05801 23 015-00498-20 TAPPING SCREW 4X6, BBX7600 1Y05801 24 667-65007-00 MUFFLER GUARD, BBX7600 1

25 073-63098-70 LABEL, BBX7600 126 450964-2 PLUG COVER, BHX2500 1

26 665-65001-00 PLUG COVER, BHX2500 127 265878-0 TAPPING SCREW BIT 5X16 9

27 015-00598-00 TAPING SCREW M5X18, BBX7600 927 015-00597-60 T. SCREW 5X16, BHX2500 4

28 667-65001-00 OIL GUARD, BBX7600 129 898454-1 CHOKE LABEL, BBX7600 1

29 641-95043-00 CHOKE LABEL, BBX7600 130 141521-4 ENGINE COVER 1 Requires 190, 191, 192

Y05801 30 667-65008-04 ENGINE COVER, BBX7600 1 Requires 190, 191, 19230 667-65008-03 ENGINE COVER, BBX7600 1 Prior to Jan 2011

31 412119-7 TUBE GUARD 20-160, BBX7600 131 085-11598-61 TUBE, BBX7600 1

32 168396-6 BREATHER, BBX7600 132 531-65033-00 BREATHER, BBX7600 1

33 125472-9 FUEL TANK CAP ASS'Y 133 592-60170-00 FUEL TANK CAP ASS'Y, BHX2500 1

34 085-13399-60 TUBE, BBX7600 135 345920-4 HOSE CLAMP 1

35 056-10599-90 HOSE CLAMP, EM4251 136 580-65029-00 FILTER, BBX7600 137 667-30060-00 FUEL TANK ASS'Y, BBX7600CA 1 BBX7600CA37 667-30020-01 FUEL TANK CPL., BBX7600 1 BBX760038 667-25003-00 ROCK RIVET, BBX7600 439 667-20020-00 GUARD COMPL, BBX7600 140 004-37061-20 SCREW ASSY M6X12, BBX7600 241 002-37060-00 FLANGE NUT, RBL500 2

Products with multiple versions are listed in subsiding order with the newest version on top not indented.Corresponding bulletins are attached. Select bulletin name or attachment to view.


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Tech Bulletins Fig. No. Part No. Description Q'ty Unit Notes


42 667-20010-00 FRAME COMPL., BBX7600 143 014-00592-10 SCREW ASSY M5X16, BBX7600 244 667-25002-00 ROCK RIVET, BBX7600 6

Y05614 45 667-20030-00 CUSHION COMPLETE 145 667-25000-00 CUSHION, BBX7600 1

46 667-50010-01 CONTROL LEVER ASS'Y, BBX7600 147 667-50010-10 S.H. BOLT M6X20, BBX7600 148 003-22060-00 WAVE WASHER, RBL500 149 003-11060-00 WASHER, RBL500 150 662-55007-01 THROTTLE LEVER 2, RBL500 151 017-00699-60 NUT, BBX7600 152 662-55006-01 THROTTLE LEVER 1, RBL500 153 662-55009-01 TORSION SPRING, RBL500 154 667-50010-30 SCREW M5X25, BBX7600 155 667-50040-00 SWITCH COMPL., BBX7600 156 667-50010-20 TAPPING SCREW 4X16, BBX7600 557 017-00599-50 NUT M5, BBX7600 158 667-55000-01 CABLE TUBE, BBX7600 159 063-01398-20 CONTROL CABLE, BBX7600 160 911253-5 P.H. SCREW M5X30 2

60 011-90595-70 S.H. BOLT M5X30 W/SW, BBX7600 260 004-36053-00 SCREW ASS'Y, RST250 2

61 597-15007-00 ROCKER COVER, BBX7600 162 597-15009-00 ROCKER COVER GASKET, BBX7600 163 597-10030-01 CYLINDER HEAD COMPL., BBX7600 164 442167-2 CYLINDER HEAD GASKET 1

64 597-15005-02 CYLINDER HEAD GASKET, BBX7600 165 065-01099-50 SPARK PLUG CMR6A, EM4251 166 011-90696-70 S.H. BOLT M6X35, BBX7600 567 597-10070-01 CYLINDER BLOCK SET, BBX7600 1

67 597-10070-00 CYLINDER BLOCK SET, BBX7600 168 424201-0 CHECK VALVE 2

68 592-15018-00 CHECK VALVE, EM4251 269 011-90699-30 H.S.H. BOLT M6X30, BBX7600 670 597-15008-00 CAMGEAR COVER GASKET, BBX7600 171 318725-5 CAMGEAR COVER, BBX7600 1

71 597-15006-00 CAMGEAR COVER, BBX7600 172 922223-9 H.S.H. BOLT M5X16 WITH WR 4

72 011-90595-31 SOCKET HEAD BOLT M5X16 472 004-36051-60 SCREW ASS'Y M5X16(W,SW),EM4251 4

73 667-60050-00 OIL CAP ASSY, BBX7600 174 021-32299-80 GASKET, BBX7600 175 346083-9 LEAD VALVE, EM2650LH

75 592-15010-00 LEAD VALVE, EM4251 176 593-15013-00 RETAINER PLATE, BBX7600 177 011-90499-80 S.H. BOLT M4X10, EM4251 178 597-65001-00 OIL CASE GASKET, BBX7600 179 597-65000-00 OIL CASE, BBX7600 180 003-70080-00 ALUMINUM GASKET, BBX7600 181 001-66081-20 BOLT M8X12, BBX7600 1

Y05470 82 011-90593-90 SOCKET HEAD BOLTM5X25, BBX7600 582 014-00596-80 SCREW M5X25, RBC230 5

83 085-11099-60 TUBE, BBX7600 184 597-20030-00 PISTON RING SET, BBX7600 1

Y05830 85 318726-3 PISTON, BBX7600 1 Implemented Feb 2011


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85 597-25000-02 PISTON, BBX7600 185 597-25000-01 PISTON, BBX7600 1

86 213599-8 OIL SEAL (S), BBX7600 186 044-01799-10 OIL SEAL, BBX7600 1

87 580-25007-02 PISTON PIN, BBX7600 187 580-25007-01 PISTON PIN, BBX7600 1

88 233995-4 CLIP, RBL500 288 056-51199-90 CLIP, RBL500 2

89 061-01299-40 NEEDLE ROLLER BEARING, BBX7600 190 032-30499-50 WOODRUFF KEY, BBX7600 191 267448-1 CLIP, BBX7600 1

91 597-25008-00 CLIP, BBX7600 192 213598-0 OIL SEAL (L), BBX7600 1

92 044-02098-90 OIL SEAL (L), BBX7600 193 597-20020-02 CRANKSHAFT COMP., BBX7600 1

93 597-20020-01 CRANKSHAFT COMP., BBX7600 1Y06029 94 331964-0 INTAKE VALVE, BBX7600 1 As a set with 94, 95, 96, 97, 198

94 597-35001-00 INTAKE VALVE, BBX7600 1Y06029 95 331965-8 EXHAUST VALVE, BBX7600 1 As a set with 94, 95, 96, 97, 198

95 597-35002-02 EXHAUST VALVE, BBX7600 195 597-35002-01 EXHAUST VALVE, BBX7600 1

Y06029 96 234212-5 SPRING, BBX7600 2 As a set with 94, 95, 96, 97, 19896 597-35003-01 VALVE SPRING, BBX7600 2

Y06029 97 331966-6 RETAINER, BBX7600 2 As a set with 94, 95, 96, 97, 19897 597-35004-00 SPRING RETAINER, BBX7600 2

98 597-35005-01 ROCKER ARM SHAFT, BBX7600 198 597-35005-00 SHAFT, BBX7600 1

Y05830 99 126005-3 ROCKER ARM ASS'Y, BBX7600 2 Implemented Feb 201199 597-30040-00 ROCKER ARM ASSY, BBX7600 2

Y05830 100 256526-2 PUSH ROD, BBX7600 2 Implemented Feb 2011100 597-35008-00 PUSH ROD, BBX7600 2

101 597-35007-00 SHAFT, BBX7600 1102 597-35006-01 CAM LIFTER, BBX7600 1103 597-30020-01 CAM GEAR ASSY, BBX7600 1104 256200-2 PIN 5 1

104 593-35001-00 ROCKER SHAFT, BHX2500 1105 597-50010-00 STARTER REWIND, BBX7600 1106 597-55000-00 PULLEY, BBX7600 1107 266585-8 TAPPING SCREW 5X12, EM2650LH 1

107 519-50020-60 SET SCREW, RBC201 1108 424516-5 COLLAR, BBX7600 1

108 597-50020-40 COLLAR, BBX7600 1109 326200-7 SWING ARM, BBX7600 2

109 597-50020-50 SWING ARM, BBX7600 2110 597-50020-30 FRICTION SPRING, BBX7600 1111 424360-0 STOPPER, BBX7600 1

111 531-50010-30 STOPPER, BBX7600 1112 530-50021-10 STARTER KNOB, RBC260 1

112 531-50010-20 STARTER KNOB, RBC311, T1 1113 597-50021-10 STARTER ROPE, BBX7600 1114 597-50020-20 REEL, BBX7600 1115 232262-4 SPIRAL SPRING, BBX7600 1

115 525-50400-30 SPIRAL SPRING, BBX7600 1116 014-00593-60 SCREW & WASHER ASS'Y 3117 667-95025-00 MODEL LABEL, BBX7600CA 1


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118 597-35012-00 CARBURETOR GASKET, BBX7600 1Y05507 119 011-90596-40 S.H.BOLT M5X25, BBX7600 2

119 014-00596-80 SCREW M5X25, RBC230 2120 597-30090-01 INSULATOR COMPL., BBX7600 1

Y05830 121 162333-2 INSULATOR GASKET, BBX7600 1 Implemented Feb 2011121 597-35011-00 INSULATOR GASKET, BBX7600 1

122 922218-2 H.S.H. BOLT M5X14 WITH WR, EM2650LH 1122 011-90594-90 SOCKET HEAD BOLT M5X14, RBC255 1122 004-36051-40 SCREW M5X14, RBC251 1

123 597-60010-00 CARBURETOR, BBX7600 1124 597-60010-10 BODY PUMP ASSY., BBX7600 1125 352010-6 INLET SCREEN, EM2650LH 1

125 501-60040-10 INLET SCREEN, RBC230 1126 442154-1 METERING DIAPHRAGM GASKET, EM265 1

126 523-60460-40 METERING DIAPHRAGM GASKET,RBC26 1127 168574-8 METERING DIAPHRAGM, EM4251 1

127 592-60080-10 METERING DIAPHRAGM, EM4251 1128 140438-8 AIR PURGE BODY, EM2650LH 1

128 523-60461-40 AIR PURGE BODY ASS'Y, EM4251 1129 424314-7 PRIMER PUMP, EM2650LH 1

129 524-60011-50 PRIMER PUMP, RBC230 1130 346270-0 PRIMER PUMP COVER, EM2650LH 1

130 523-60460-50 PRIMER PUMP COVER, EM4251 1131 266582-4 TAPPING SCREW 3X24, EM2650LH 4

131 523-60460-10 PUMP COVER SCREW, RBC230 4132 266795-7 ADJUST SCREW 1

132 521-60080-10 CABLE ADJUST SCREW, RBL500 1133 264065-8 CABLE ADJUST NUT, RBC230 1

133 531-60054-50 CABLE ADJUST NUT, RBC230 1134 325922-6 SWIVEL, EM2650LH 1

134 523-60180-40 SWIVEL, RBC230 1135 413140-9 WASHER, EM2650LH 1

135 542-60050-30 WASHER, EM4251 1136 266704-6 PAN HEAD SCREW M3X10, BBX7600 2

136 524-60012-40 THROTTLE COLLAR SCREW, RBC230 2137 523-60520-20 BRACKET CABLE, MS3200 1138 257964-1 STOP RING E-3, EM2650LH 1

138 531-60051-20 RING, RBC230 1139 424444-4 PACKING RING, BBX7600 1

139 523-60180-20 RING PACKING, RBC230 1140 234183-6 CONICAL COMPRESSION SPRING 5-9, E 1

140 592-60020-20 PUMP SPRING, EM4251 1141 213538-8 O RING 2, EM2650LH 1

141 524-60010-10 O RING, RBC230 1142 597-60010-20 JET #60, BBX7600 1143 442155-9 PUMP GASKET, EM2650LH 1

143 592-60020-40 PUMP GASKET, EM4251 1144 168575-6 PUMP DIAPHRAGM, EM2650LH 1

144 524-60010-40 PUMP DIAPHRAGM, RBC230 1145 667-65012-00 KNOB BOLT, BBX7600 2146 667-60020-02 AIR CLEANER COVER, BBX7600 1147 667-65002-01 AIR CLEANER ELEMENT, BBX7600 1148 004-36051-60 SCREW ASS'Y M5X16(W,SW),EM4251 4149 667-60030-02 AIR CLEANER CASE ASSY, BBX7600 1150 667-65013-00 SEPARATOR PLATE, BBX7600 1151 424315-5 CHECK VALVE, EM4251 1


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151 531-65007-01 CHECK VALVE, EM4251 1152 424316-3 CHECK VALVE, EM2650LH 1

152 592-35024-00 CHECK VALVE (1), EM4251 1153 667-65005-00 CHECK VALVE PLATE, BBX7600 1154 085-11399-20 TUBE, BBX7600 1155 056-10799-90 HOSE CLAMP, BBX7600 1156 422096-5 TUBE, BBX7600 1

156 085-10299-30 TUBE, BBX7600 1157 452952-5 HOSE JOINT, BBX7600 1

157 597-35022-00 JOINT PIPE, BBX7600 1158 085-11999-60 TUBE, BBX7600 2159 597-30060-00 INTAKE CASE ASSY, BBX7600 1160 597-35018-00 CHOKE LEVER, BBX7600 1161 597-35017-00 CHOKE PLATE, BBX7600 1162 597-30060-10 TAPPING SCREW 4X12, BBX7600 2163 597-35019-00 INTAKE PLATE, BBX7600 1164 014-00594-70 SCREW M5X62, RBC256 2

164 004-36056-50 SCREW M5X62, RBC251 2165 056-16799-90 HOSE CLAMP, BBX7600 1166 056-14399-90 HOSE CLAMP, BBX7600 1167 667-65004-00 AIR CLEANER DUCT, BBX7600 1168 597-35013-01 MUFFLER GASKET, BBX7600 1169 597-30010-02 EXHAUST MUFFLER, BBX7600 1170 020-00698-90 WASHER, BBX7600 3171 011-90696-50 S.H. BOLT M6X70, BBX7600 3172 424105-6 PLUG CAP, EM4251 1

172 592-75001-00 PLUG CAP, EM4251 1173 324891-8 PLUG CAP SPRING, EM2650LH 1

173 065-40099-31 PLUG CAP SPRING,RBC221 1174 011-90499-70 SOCKET HEAD BOLT, BBX7600 2175 638784-6 WIRE, RBC201 1

175 616-55002-01 WIRE, RBC201 1176 638710-5 WIRE 2, BHX2500 1

176 592-70110-00 WIRE 2, BHX2500 1177 597-70010-10 IGNITION COIL, BBX7600 1178 597-70010-20 FLYWHEEL COMP., BBX7600 1179 264054-3 FLANGE NUT M10, BBX7600 1

179 002-37100-00 FLANGE NUT M10, BBX7600 1180 667-90020-00 SWIVEL PIPE COMP., BBX7600 1181 056-17699-90 HOSE CLAMP, BBX7600 1182 667-95000-00 FLEXIBLE PIPE, BBX7600 1183 056-10099-90 HOSE CLAMP, BBX7600 1184 667-95018-01 STRAIGHT PIPE, BBX7600 1185 667-95019-00 END PIPE, BBX7600 1186 667-90010-00 BAND COMPL., BBX7600 2187 597-35023-00 CAM LIFTER (EXHAUST SIDE), BBX7600 1

Y05795 188 667-25004-00 FAN COVER, BBX7600 1Y05795 189 667-25003-00 ROCK RIVET, BBX7600 2

190 443174-8 INSULATION LABEL A 1 Not included with Fig No 30Y05801 190 667-65015-00 INSULATION LABEL 1 Not included with Fig No 30

191 443175-6 INSULATION LABEL B 1 Not included with Fig No 30Y05801 191 667-65016-00 INSULATION LABEL 1 Not included with Fig No 30

192 443176-4 INSULATION LABEL C 1 Not included with Fig No 30Y05801 192 667-65017-00 INSULATION LABEL 1 Not included with Fig No 30Y06029 198 331967-4 COTTER, BBX7600 4 As a set with 94, 95, 96, 97, 198


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Page 17 of 17 PB_12-2012_rev 11

ECHNICAL INFORMATION

For Models

Country

T Y05468August 2009

Change of Screw Ass'y M5x16 (W,SW)

BBX7600, FLH7500, PB7600.4

All countries

Subject

Description

Cylinder block set

Camgear covergasket

Camgear cover

Changed

Screw Ass'y M5x16 with Flat washer and Spring washer has been replaced by Socket head bolt M5x16 with Flat washer and Spring washer.See illustration below.

Current part New part NoteQ'tyItem No.

4

I/CQ'ty

Interchangeability(I/C)

4072 YesScrew Ass'y M5x16(W,SW)

0043605160

Socket Head Bolt M5x16(W,SW)

0119059531

Already implemented since May 2009 production

Implementation


For Models

Country

T Y05470August 2009

Change of M5x25 Screw and Screw Ass'y

BBX7600, PB7600.4

All countries

Subject

Description

M5x25 Screw with flat washer and spring washer for Oil case

M5x25 Socket head bolt with flat washer and spring washer for Oil case

Pan head screws have been replaced by Socket head bolts to ensure the complete fastening. See illustration below.

Current part New part Note

The current partsremain available.

Q'tyItem No.

5

I/CQ'ty


5082 YesScrew M5x25

0140059680

Socket Head Bolt M5x25

0119059390

22060 YesScrew Ass'y

0043605300

Socket Head Bolt M5x30W/SW

0119059570

1

2 Screw ass'y with flat washer and spring washerfor Rocker cover

M5x30 Socket head bolt with flat washer and spring washer for Rocker cover

Already implemented since July 2009 production

Implementation


For Models

Country

T Y05353March 2009

Change of Cam Lifter on Gas Exit Side

BBX7600, PB7600.4, FLH7500

All countries

Subject

Description

Cam Lifter

Cam lifter on exhaust side has been changed to enhance the engine durability.See illustration below for the detail.

Current part New part NoteQ'tyItem No. I/CQ'ty


597350060112102 No

Interchangeableas a set

Cam Lifter

5973500601

1187Cam Lifter

5973502300

Current New

Exhaust sideCam lifter: 5973502300

Both exhaust and intake sidesCam lifters : 5973500601

7mm5mm

Intake side (The cam lifter remains 5973500601.)

1) Rib is added as a distinction of the new from the current. 2) The contact area is enlarged.

Already implemented since November 2008 production

Implementation


For Models

Country

Description

T Y06029June 2012

(Page 1 of 6)Change of Specifications

BBX7600, FLH7500, PB7600.4, PB7601.4CA

A

BBX7600: Australia, Brazil, Canada, Chile, China, Italy, Korea, Mexico, Netherlands, New Zealand, Panama, Switzerland, Taiwan. UK, VietnamFLH7500: Australia, ItalyPB7600.4: Austria, France, Germany, Italy, Netherlands, Spain, SwedenPB7601.4CA: USA

Subject

The following parts have been changed / added to standardize the specifications to those of new model such as Mist blower. Refer to the numbers shown in the list of Pages 4, 5 and 6.

The groove is modified.

modified changed

added

The groove is modified.

modified

Oil return passage is added here.

Around Valve

B Around Cylinder head

6

7

34 34

5 5

211

Oil return passage was here.

Change of Outer diameter of Rocker arm shaft

Change of Muffler

Guide pipe (Three positions)

Burring

Sleeve (Three positions)

9

10 24

Addition of Exhaust port spacer

8 6Rocker arm assembly is treated as the component of .However, the current parts remain available.

ø50-0.010 ø50

-0.002

Oil return passage is eliminated.

ø5+0.003-0.009

ø5-0.003-0.015

Hole for inserting Rockershaft is changed fromto

Burring portion is eliminated.

Y06029(Page 2 of 6)

B Around Cylinder head (cont.)

Change of Bolt for securing Muffler

Change of Tube (one of Two tubes is changed.)

Addition of Tubes to protect the original tubes

Change of Case 2 volute assy

Washer M6x70 M6x18

13-1 13-2

15 1614

1817

1211

12 11111111

Overall length: 190mm

220mm tube110mm tube

170mm tube

Rib iseliminated.

Overall length: 240mm

Original tubes

Three tubes are added on the original tubes.

Y06029(Page 3 of 6)

C The others

Change of Crank pin of Crank shaft complete (material / Carbrizing hardness)19

Change of Piston pin (material / Carbrizing hardness)20

Change of the crank case portion of Cylinder block set21

Change of Rocker cover22

Change of part number of Tube

Rib is added.

23

Change of Socket head bolt for securing Insulater (Surface treatment / Adhesive to put on the thread)25

Change of part number of Tube

ThreeBond 1344Black wash

SCM415HRC60~64

SCM420HHRC62 or more

ThreeBond 2466Chromate treatment

26

SCM415HRC60~64

SCM420HHRC62 or more

Pilot hole to insert Pipe joint was here. Pilot hole to insert

Pipe joint is changed here.

Eliminated

Y06029(Page 4 of 6)


198

097

094


Interchangable as a set with

Treat the new Shaft rocker arm and Rocker arm assemblyas the components of .

Q'tyI/CQ'tyItem No.

2Retainer331966-6

4*331967-4

*Two Cotters are used for intake side and exhaust side. (Four cotters in total)

Spring retainer

Cotter

Intake valveIntake valve

Exhaust valveExhaust valve

Compression spring 11Valve spring

Cylinder head complCylinder head compl

59735004002 No

No

No

1331964-05973500100

1

095

096

1331965-85973500202 1

2234212-55973500301 2

063

098

159710030025971003001

1

Shaft5973500500

1

No

No

1Shaft rocker arm5973500501

199 1Exhaust port spacer331937-3

169 1Muffler exhaust5973001003

099 2Rocker arm assembly126005-3

Rocker arm assembly

Exhaust muffler

126005-3 2 Yes

Yes

1

3 No

No

No

171 3Socket head bolt M6x18266771-1

Socket head bolt M6x700119069650

1Tube 3-190

0851199960 0851199960Tube 3-190

170

1

2

3

4

5

6

7

9

10

8

11

12Washer0200069890

3

2158

5973001002

1Tube 10-110412123-6

14 200

202 1Tube 10-220412124-4

019 1Case 2 volute assy6671006002

201 2Tube 10-170412127-8

Rocker cover

Case 2 volute assy1

1019 1Case 2 volute assy6671008002

Volute case 2 assy6671008001

1Piston pin

5802500701 5802500702Piston pin

093

16

17

15

18

20

19Crankshaft compl5972002001

Crankshaft compl5972002002

1 1

1

1

1

087

6671006001

1Cylinder block set

5971007000Cylinder block set

597100700121 067

1Rocker cover

5971500700 597150070122 061

Yes

Yes

13-1

6

, or9 11 12 1413-1 13-26

16 17 18 10 2415


, or9 11 12 1413-1 13-26

16 17 18 10 2415


, or9 11 12 1413-1 13-26

16 17 18 10 2415


, or9 11 12 1413-1 13-26

16 17 18 10 2415

Interchangable as a set with9 1110 12

1413-1

13-26

16 17 1815

Interchangeability mark; The arrow means that the new part can be substituted for the current.

For intake side( side)

Interchangeableas a set with

3

1 2 3 5

1

For exhaust side( side)

Interchangeableas a set with

4

2 4 5

Yes

Yes

Y06029(Page 5 of 6)




Q'tyI/CQ'tyItem No.

Australia Brazil Canada SwitzerlandChile China UK

169 1Muffler exhaust5973001003

Exhaust muffler1

2

Yes

Yes

No

119 2Socket head bolt M5x25with WR266749-4

Socket head bolt M5x25 The current parts remainavailable.0119059640

1Tube 3-240412122-8

156

24

25

13-2

26Tube0851029930

Tube 3-25422096-5

1 1

203

5973001001

2425

13-226

13-1

212223

181920

151617

12

14

91011

678

345

12

, or9 11 12 1413-1 13-26

16 17 18 10 2415

Interchangable as a set with9 11 12 1413-1 13-26

16 17 18 2415


Implementation

From November 2011 production

Refer to the applicable parts listed below and next page. BBX7600

Italy Korea Mexico Netherlands Panama Taiwan Vietnam

154 1Tube 3-130412121-0

Tube0851139920

1 Yes23

Y06029(Page 6 of 6)

Austria France Germany Australia

2425

13-226

13-1

212223

181920

151617

12

14

91011

678

345

12

PB7600.4 PB7601.4CA FLH7500Italy Netherlands Spain Sweden ItalyUSA


For Models

Country

T Y05507December 2009

Change of M5x25 Socket Head Bolt

BBX7600, FLH7500, PB7600.4

G3501R: countries using Battery bolt completeG3511R, G4101R, G5501R, G5711R, G6101R: Canada, USA

Subject

Description M5x25 Socket head bolt has been replaced by one with adhesive to prevent bolt from loosening.


01190596400119059390

Socket Head Bolt M5x252 2119




M5x25 Socket Head Bolt(2pcs.)

Already implemented since July 2009 production

Implementation


For Models

Country

T Y05380March 2009

Change of Exhaust Muffler

BBX7600, PB7600.4

All countries

Subject

Description

Exhaust Muffler

Indication on Exhaust muffler has been changed as illustrated below.



597300100111169 Yes

Exhaust Muffler

MAKITA5973001002

ROBIN5973001001

5973001002

Current New

Already implemented since August 2007 production

Implementation


For Models

Country

T Y05611June 2010

Change of Exhaust Valve

BBX7600, PB7600.4, FLH7500

All countries

Subject

Description

5973500202

For further enhancement in durability of Engine, tufftride process has been done to Exhaust valve.



11095 YesExhaust Valve

5973500201

Exhaust Valve

Already implemented since April 2009 production

Implementation


For Models

Country

T Y05795February 2011

Addition of Fan cover

BBX7600, FLH7500, PB-7600.4

All countries

Subject

Description Fan cover has been secured with two Rock rivets as drawn below.



16672500400

188

Fan cover(6672500400)

Fan cover

26672500300

189Rock rivet

Rock rivet(6672500300)

(Frame complete)

ImplementationFrom December 2010 production


For Models

Country

T Y05677September 2010

Change of Piston

BBX7600, FLH7500, GSH8100R, PB7600.4, WFLH7500

All countries

Subject

Description

The durability is increased.

Piston has been modified as illustrated below.



15972500002

15972500001Piston Piston

085 Yes

Current New

R3 3.2 R4

SR150

ImplementationFrom September 2010 production


For Models

Country

T Y05614June 2010

Change of Cushion

BBX7600, PB7600.4, FLH7500

All countries

Subject

Description

6672003000

Cushion has been changed as illustrated below.The assembling way remains the same.



11045 YesCushion Complete

6672500000

Cushion

Already implemented since April 2010 production

Implementation


For Models

Country

T Y05301November 2008

Change of M5x25 Screw and M5x14 Screw Ass’y

BBX7600, PB7600.4

All countries

Subject

Description

Screw M5x25

0140059680


0119059390

M5x25 Screw has been replaced by M5x25 Socket head screw.M5x14 Screw ass’y has been replaced by M5x14 Socket head bolt (W, SW).

Current part New part NoteQ'tyItem No.

119 22

I/CQ'ty


Screw Ass’y M5x14

0043605140

Socket Head Bolt M5x14(W,SW)

0119059490

122 Yes

Yes

11

119

122

BBX7600: From February 2008 productionPB7600.4: From March 2008 production

Implementation


For Models

Country

T Y05830 March 2011

Change of Piston, Push rod, Rocker arm assy and Insulator gasket

FLH7500 BBX7600 PB7600.4

All countries

Subject

Description

1. Modification on Piston design

2. Change of the material of Push rod and additional treatment of gas nitrocarburizing on Push rod surface

3. Addition of Gas nitrocarburizing treatment to the surface of Adjust screw of Rocker arm assy

4. Modification of design and material of Insulator gasket

Piston, Push rod, Rocker arm assy and Insulator gasket have been modified to increase the enginedurability.

Current part New part NoteQ'tyI/CQ'ty


Item No.

2

2

2

2

100

99

Push rod5973500800

Push rod256526-2

Rocker arm assy5973004000

Rocker arm assembly126005-3

1 185 YesPiston

5972500002

Piston

318726-3

1 1121 YesInsulator gasket5973501100

Insulator gasket162333-2

Yes

Yes

Material: SWB; wire steel

Material: SUS (stainless steel)treated by gas nitrocarburizing

Push rod

[Current]

[Current]

[New]

[New]

R5.0

[Current] [New]

Adjust screw

Designchange

Materialchange

ANP sheet;Heat-resistancecarbon resin

Meta-foam; Metal sheet coated by oil-resistance foam-rubber

ImplementationFrom February 2011 production

SERVICE notes 2012-13

Page 1 of 4

Subject Replacing and installing valves on BBX7600 blower

For model BBX7600, BBX7600CA, BBX7600N

Country USA

Description Design change YO6029 was implemented in March 2012. The components of the valve train have been modified to improve the durability of many of the valve train components

UReference repair manuals: Service Manual_ BBX7600, BBX7600CA (pages 43-44) Technical Bulletin YO6029 USpecifications

New or revised components (94, 95, 96, 97 and 198) can be used in any BBX7600 cylinder head. Parts should be installed as a set. Parts needed: UFig.U UPart NumberU UDescriptionU UQtyU 94 331964-0 Intake valve, BBX7600, Type 2 1 95 331965-8 Exhaust valve, BBX7600, Type 2 1 96 234212-5 Spring, BBX7600, Type 2 2 97 331966-6 Retainer, BBX7600, Type 2 2 198 331967-4 Cotter, BBX7600, Type 2 4 UTools SAE 10W-30 oil Magnet Cotter removal and installation special tool (Makita pn 1R389 and 1R005) or special tool see photo #1

UEstimated valve removal or installation time 5 minutes

Cotter Installation end Cotter Removal end

Photo 1


Page 2 of 4

UValve removal procedure

1. Remove the cylinder head from the top of the cylinder

2. The rocker arms do not have to be removed. In

photo #2 the rocker arms have been removed.

3. Block the valves with 1/8” thick piece of cardboard or metal to prevent the

valves from opening during retainer cotter removal.

4. With removal tool in one hand and magnet in the other, press down on the top of the retainer with tool. See photo #3.

5. Remove the cotter with the magnet. See photo #4.

6. Repeat until all 4 cotters are removed.

7. Remove the springs and valves

UCotter and retainer installation preparation

8. On small piece of paper or business card prepare the 2 cotters as shown

9. Place the retainer on top of the cotters as shown above.

10. Holding paper turn over the cotter and retainer assembly. Remove paper.

11. Repeat with other retainer and cotters.

Photo 4

Photo 3

Photo 2


Page 3 of 4

U Prepare Cylinder head and valves for installation

12. Coat or wipe down the intake and valve exhaust valve stems with 10-W30 oil. Remove all excess oil.

13. Install the intake and exhaust valves into the cylinder head

14. Block the valves with 1/8” thick piece of cardboard or metal to prevent the

valves from opening during retainer cotter installation.

15. Place the cylinder head on a flat surface.

URetainer and cotter installation

16. Install spring onto each valve.

17. Place a retainer/cotter assembly on top of the exhaust valve. See photo #5.

18. Place the installation tool with counter bore on top of the retainer cotter assembly. See photo #6.

19. Pressing down on the installation tool, guide the valve stem through the hole and cotters into position. See photo #7.

20. The valve stem should extend up through the installation tool as in photo #7.

Photo #7

Photo #6

Photo #5


Page 4 of 4

21. Remove the installation tool and check to see if cotters are installed correctly as in Photo #8.

22. Repeat for the intake valve. Both intake and exhaust valves should be the same. See photo #9.

Photo #8

Photo #9

Implementation All USA 4-stroke air cooled OPE products. Recommend that any product delivered for maintenance be checked.


For Models

Country

Description

T Y05071October 2007

Change of Exhaust Valve

BBX7600, PB7600.4

BBX7600: Canada, Italy, Netherlands, Panama, Switzerland, UKPB7600.4: Austria, France, Germany, Italy, Netherlands, Spain, Sweden,

095

Exhaust valve has been changed to increase durability.See illustration below.

Subject

1

From September 2007 production.


Implementation


Exhaust Valve

59735002011

Exhaust Valve

5973500200Yes

ø18.

9+0.

1

ø18.

5+0.

1

ø4

-0.

035

ø4

-0.

050

-0.0

35

-0.0

20

Current New


For Models

Country

T Y05509December 2009

Change of 5x16 Tapping Screw

BBX7600, FLH7500, PB7600.4

All countries

Subject

Description

Item No. 0095x16 Tapping screws (9pcs.)

Item No. 009M5x18 Tapping screws (9pcs.)

5x16 Tapping Screw has been replaced by M5x18 Tapping screw to prevent the looseness.




Item No. 0275x16 Tapping screws (4pcs.)

Item No. 027M5x18 Tapping screws (4pcs.)

01500598000150059760

Tapping Screw 5x16 Tapping Screw M5x189 9009

01500598000150059760

Tapping Screw 5x16 Tapping Screw M5x184 4027

Already implemented since November 2009 production

Implementation


For Models

Country

T Y05801February 2011

Change of Engine cover, Muffler guard and 4x6 Tapping screw

BBX7600, PB7600.4, FL-H7500, GSH8100R, W-FLH7500

All countries

Subject

Description Engine cover, Muffler guard and 4x6 Tapping screw have been changed as drawn below to comply with the clause of EN15503.


16676500804

1 NoBBX7600(Makita blue)PB7600.4(Dolmar orange)FLH7500(red)

Interhcnageableas a set with

Insulation labelGSH8100R (yellow) for• MULTIPOWER • W-FLH7500 for WORMS

0306676500803Engine cover

Engine cover

Engine cover

166765009041 No030 6676500903Engine cover Engine cover

16676500004

1 No0306676500003Engine cover Engine cover

16676501004

1 No6676501003Engine cover Engine cover

Insulation label

Insulation labels

Slits are filled with1mm thickness of the Insulation labels.

Their labels areattached to the reverse of Engine cover.

Insulation label

Insulation label

10246676500700Muffler guard

10230150049820Tapping screw 4x6

16676501500

190


1

1 2 3 4

2

3

4

5

5

6

7

7

8

9

16676501600

1918

16676501700

1929

Interhcnageableas a set withEngine cover

Engine cover

Exhaust air outlet is modified.

Slits are eliminated.

1 2 3 4Muffler guard

64x6 Tapping screw

ImplementationEurope: From January 2011 productionThe others: On or after January 2011 production

Documents

BBX7600 PARTS BREAKDOWN BBX7600CA PARTS BREAKDOWN · PDF filePARTS BREAKDOWN EM4251 ... modi˜ed. modi˜ed changed added ... CRANKSHAFT COMP., BBX7600. 1. 93. 597-20020-01. CRANKSHAFT