Echo CS-2510TES, Service Manual

Page 1: ...Ref No 401 39 CS 2510TES ECHO shindaiwa 250Ts 250TCs Serial number 37000001 and after ...

Page 2: ...ting guide that describes problems testing remedies and references We recommend you make use of Operator s Manual and Parts Catalogue together with this manual when servicing We are constantly working on technical improve ment of our products For this reason technical data equipment and design are subject to change without notice All specifications illustra tions and directions in this manual are ...

Page 3: ... 12 Inspecting diaphragm and others 39 4 13 Replacing welch plug 39 4 14 Installing carburetor 40 5 CLUTCH SYSTEM 41 5 1 Inspecting clutch parts 41 5 2 Replacing clutch parts 43 5 3 Installing clutch assembly 43 6 CHAIN BRAKE SYSTEM 44 6 1 Replacing brake lever and torsion spring 44 6 2 Inspecting chain brake parts 46 7 SAW CHAIN LUBRICATION SYSTEM 48 7 1 Inspecting oil cap and strainer 48 7 2 Ins...

Page 4: ...ion Type CDI Capacitor discharge ignition system Digital magneto Spark plug CMR7H Starter Type ES effortless start S Soft start Rope diameter x length mm in 3 0 x 720 0 12 x 28 3 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Petrol Minimum 89 octane petrol Two stroke air cooled engine oil ISO L EGD ISO CD13738 JASO FC FD Tank capacity L UK fl oz 0 19 6 7 Exhaust Muffler type Spark arrest...

Page 5: ... turn out 1 7 8 H mixture needle initial setting turn out 2 5 8 Test Pressure minimum MPa kgf cm2 psi 0 05 0 5 7 0 Metering lever height mm in 1 65 0 06 lower than diaphragm seat Chain oil discharge volume Adjustable 1 5 13 0 05 0 46 Factory set 7 mL min mL min UK fl oz min BTDC Before top dead centre With 25 cm guide bar and properly tensioned saw chain Set throttle adjust screw to the point that...

Page 6: ...dle rear side M4 20 30 2 3 20 25 Spring M4 20 35 2 3 5 20 30 Brake cover M4 20 30 2 3 20 25 Sprocket guard plate Sproket guard side M4 20 30 2 3 20 25 Brake lever Hand guard M5 30 45 3 4 5 25 40 Chain catcher M5 30 45 3 4 5 25 40 Stud bolt M8 150 200 15 20 130 220 Bolt at guide bar mount M5 30 45 3 4 5 25 40 Guide bar nut M8 120 150 12 15 105 135 Regular bolt nut and screw M3 6 10 0 6 1 5 9 M4 15 ...

Page 7: ... 375 C Piston pin bore Max 8 035 0 3163 D Piston ring groove Max 1 3 0 051 E Piston ring side clearance Max 0 1 0 004 F Piston pin outer diameter Min 7 98 0 3142 G Piston ring width Min 1 15 0 045 H Piston ring end gap Max 0 5 0 02 K Con rod small end bore Max 11 03 0 4341 L Crankshaft runout Max 0 02 0 001 M Sprocket bore Max 13 07 0 5146 N Clutch drum bore Max 53 5 2 11 P Sprocket wear limit Max...

Page 8: ...embly 13 91037 Compression gauge Measuring cylinder compression 14 X681 000000 Adapter M10 Measuring cylinder compression for 10mm dia spark plug 15 897826 16131 Pressure rubber plug Plugging intake port to test crankcase cylinder leakages 16 897827 16131 Pressure plate Plugging intake port to test crankcase cylinder leakages 17 91041 Pressure rubber plug Plugging intake port to test crankcase cyl...

Page 9: ...in cylinder 6 When accumulated energy in power spring F overcomes the load from compression pressure in cylinder crankshaft is rotated 7 Power spring F absorbs compression resistance of cylinder and snatch back of engine during starting action 8 When starter rope J is released rope reel E is returned together with power spring F and pawl catcher G by rewind spring tension 9 After engine starts sta...

Page 10: ...in rope reel notch c as shown 4 Rotate rope reel C counterclockwise to release tension of rewind spring 5 Remove screw D 6 Remove pawl catcher E and power spring F 7 Remove rope reel C from starter case G slowly to prevent rewind spring H from unwind ing 8 Remove rewind spring case assembly J from starter case G WARNING DANGER Wear eye protection and take care when removing rope reel Rewind spring...

Page 11: ...e rope through hole of rope reel C then press the knot D into recess as shown 3 When installing a new starter rope singe both ends of the rope to prevent fraying 5 Pass the other end of starter rope through start er case from inside to outside 6 Pass starter rope through starter grip E Make a knot as shown 7 Tighten knot F Push the knot F into recess of starter grip E 4K287 A B C D D F C C E ...

Page 12: ... case B before wind the spring 2 Carefully install rewind spring case assembly C on starter case matching hole c with post D Hook a of rewind spring should contact with post E of starter case 3 Wind the rope G on rope reel F 2 turns as shown 4 Apply small amount of lithium based grease to starter case side f1 of the rope reel F 5 Assemble rope reel F engaging hook f2 with hook a of rewind spring A...

Page 13: ...e f4 9 Install pawl catcher J engaging hole j with power spring top end hook h2 10 Reinstall screw K on starter post 11 Pull out starter rope inside starter case Rotate rope reel F clockwise 3 turns with starter rope hooked at notch f5 as shown Hold rope reel F to prevent it from unwinding and pull out starter grip to take the rope slack 12 Pull starter several times to check rewind spring tension...

Page 14: ...arter assembly from unit 2 Loosen bolt A and remove pawl B and torsion spring C Replace damaged or worn parts NOTE When it is hard to loosen bolt install clean rope D in spark plug hole E to stop crankshaft rotation and remove bolt easily 3 Install torsion spring C pawl B and bolt A To avoid pinching of torsion spring C install these parts without setting the end c of torsion spring C on starter p...

Page 15: ...SYSTEM CS 2510TES 250Ts 250TCs 13 3 IGNITION SYSTEM A Ignition switch B Spark plug C Spark plug cap coil D Spark plug cap E Ignition coil F Bolt M4 G Collar H Flywheel J Nut M8 K Woodruff key B C D E H J F A G K ...

Page 16: ... Not OK Not OK S T OK S T Not OK Pole shoe air gaps Replace OK OK Leads connections Not OK OK OK Not OK S T Repair Replace Not OK Remedy Inspect Not OK Woodruff key End Not OK Flywheel magnet Replace R T OK OK Replace ignition coil and or inspect other systems Replace flywheel OK OK S T S T Spark test R T Running test including actual cutting OK Adjust pole shoe air gaps S T OK Not OK Not OK Not O...

Page 17: ...Turn ignition switch to RUN position Pull start er grip several times 6 If spark is steady blue or white at the tester gap ignition system is considered good 7 If no spark exists or spark is intermittent in yellow orange or red continue with further inspec tion WARNING DANGER Do not test near spark plug hole without spark plug installed otherwise there is a chance to ignite fuel mixture inside cyl...

Page 18: ...ry If it is exces sively wet or dry inspect fuel system A B 3 4 Replacing spark plug cap and coil 1 Disconnect spark plug cap A from spark plug 2 Apply some oil in spark plug cap A for easy re moval from high tension lead B 3 Pull spark plug cap away from high tension lead 4 Inspect spark plug cap coil C for corrosion and correct connection Inspect spark plug cap for cracks Replace as required NOT...

Page 19: ...ester should indicate infinite resistance 4 When ignition switch is in STOP position tes ter should show that the circuit is in conducting state closed circuit 5 If ignition switch is defective replace with a new one B A E C D B 3 6 Replacing ignition switch Removing 1 Remove starter assembly from unit 2 Remove bolt A ignition switch terminal B and C from ignition coil D 3 Insert screwdriver or eq...

Page 20: ...cing ignition switch Continued 4 Loosen nut F and remove sprocket guard G 5 Remove bolt H chain catcher J and sprocket guard plate K 6 Remove bolt L and brake lever M 7 Remove plug N and bolt P 8 Remove bolt Q and rear handle lid R F G H K J P N Q R M L ...

Page 21: ...passing switch lead t1 and t2 through notch on rib U1 U2 and U3 11 Insert rear part of rear handle lid R to hole v1 on rear handle assembly V as shown 12 Assemble rear handle lid R as rib v2 on rear handle assembly V enters into rear handle lid R 13 Tighten M5 bolt P and M4 bolt Q 14 Install plug N R v1 V v2 R P N Q V v2 R Section view V S U1 t1 t2 U2 U3 ...

Page 22: ...ition coil 3 8 Setting pole shoe air gaps 17 Pass switch lead t1 for terminal B through notch X then pass switch lead t2 for terminal C over the lead t1 18 Set switch lead t1 and t2 between engine cover and ignition coil D as shown 19 Pass switch lead t1 through four guides Y then pass switch lead t2 over the lead t1 20 Place fuel lines W as shown 21 Insert projection e1 on dust cover to hole on e...

Page 23: ...inued 22 Insert front starter side tab e2 on dust cover into engine cover 23 Insert rear clutch side tab e3 on dust cover into engine cover 24 Insert front clutch side tab e4 on dust cover into engine cover with screwdriver or equivalent 25 Reassemble all removed parts e3 e2 e4 ...

Page 24: ...ll spark plug cap and spark plug cap coil to new ignition coil F 8 Apply a drop of thread locking sealant Loc tite 222 or ThreeBond 1344J or equivalent to tapped hole H of cylinder 9 Set collars J as shown 10 Loosely install new ignition coil F and ignition switch terminal E with bolts D through collars J Set pole shoe air gaps Refer to 3 8 Setting pole shoe air gaps Tighten two bolts D 11 Connect...

Page 25: ...1004 B or feeler gauge NOTE When air gap is too narrow contact with flywheel may result When the air gap is too wide spark is weak 4 Reassemble all removed parts D C A 3 9 Inspecting flyweel and key 1 Inspect magnetic force of flywheel A using flux meter or screwdriver B as shown 2 If magnetic force is weak replace flywheel A as follows 3 Open cap cover C Disconnect spark plug cap and remove spark...

Page 26: ...er alternately to remove flywheel A 8 Inspect woodruff key H for damage or shear ing Replace as required 9 Wipe off oil from taper part of crankshaft and fly wheel before assembling flywheel 10 Install woodruff key H into key groove 11 Reinstall starter pawls Refer to 2 4 Replacing starter pawl 12 Align flywheel key groove with woodruff key on crankshaft Install flywheel and fasten flywheel nut cl...

Page 27: ...E Connector F Fuel tank G Fuel tank vent H Fuel strainer J Clip K1 Fuel line in fuel tank K2 Fuel line 3x5x95mm K3 Fuel line L Grommet M Joint L shaped black N Joint black P Purge line L shaped Q Purge bulb R1 Fuel return line 3x5x58mm R2 Fuel return line 3x5x115mm S Joint white T Intake bellows U Collar V Collar W Bolt M4 X Carburetor Y Carburetor elbow Z Bolt M5 ...

Page 28: ... If blocked with dirt or dust remove the obstruction with using brush 7 If heavily blocked with dirt or dust clean air filter with compressed air or wash it in non inflammable solvent WARNING DANGER Wear eye protection when working with compressed air Eye damage can occur from flying particles 8 If heavily blocked with dirt or dust or if heavily soiled or damaged replace with new one 9 Dry air fil...

Page 29: ...p 2 Inspect fuel cap for cracks and gasket A for cuts or damage and replace with new one as re quired 3 Replace connector B if damaged 4 Pull fuel strainer C out from fuel tank using a wire hook D Clean fuel strainer C Replace with new one if defective or heavily soiled 5 Reinstall fuel cap A B C D ...

Page 30: ...TE Wrap the ends of longnose pliers with tape J or cover with soft pipes to protect fuel line from damage 6 Apply pressure approx 50 kPa 0 5 kgf cm2 7 psi 7 If pressure drops replace with new fuel line Re fer to 4 6 Replacing fuel line and fuel return line 8 Put fuel strainer in fuel tank and fasten fuel cap securely 9 Apply pressure approx 10 kPa 0 1 kgf cm2 1 4 psi 10 Pressure should not drop If...

Page 31: ...A from grommet B 3 Connect tank vent A to pressure tester 91139 C 4 Apply pressure approx 50 kPa 0 5 kgf cm2 7 psi Make sure pressure is stable in range of 10 40 kPa 0 1 0 4 kgf cm2 1 4 5 7 psi 5 If it is not in the range gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valves in tank vent as sembly Damage to valves will occur 6 Apply negative pressure 20 ...

Page 32: ...ange gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valves in tank vent as sembly Damage to valves will occur 4 Remove cap C of tank vent and clean sponge D 5 Cut pipe 363011 00210 E 7x11x170mm and 382011 01110 F 9x13x350 in approx 30mm 1 1 4 in length and connect them to pressure tester as shown Connect tank vent A without cap to pipe as shown 6 Plug ho...

Page 33: ...retor 3 Press leg a1 of purge bulb A with screwdriver to remove purge bulb A from rear handle 4 Disconnect parge line B and fuel return line C from purge bulb A Installing 5 Connect fuel return line C to longer fitting a2 of purge bulb A Connect purge line B to shorter fitting a3 of purge bulb A 6 Push purge bulb A into rear handle 7 Reassemble removed parts Refer to 4 14 In stalling carburetor A ...

Page 34: ... remove fuel line D black joint B and fuel return line H from grommet K 6 Inspect fuel line D joint B fuel return line H and grommet K Replace with new one if defec tive 7 To replace fuel line M and fuel return line N disconnect fuel line M from black joint C and fuel return line N from white joint J 8 Remove air cleaner cover air filter carburetor elbow and carburetor 9 Remove fuel line M from re...

Page 35: ... B in grommet K as brim b of joint B touches grommet K 16 Adjust direction of fuel line A and joint B as view R 17 Reinstall fuel return line H through grommet K as shown 18 Reinstall assembled grommet K on the unit as shown And connect fuel line A to black joint C and fuel return line H to white joint J respec tively 19 Pass fuel line A as shown then fuel return line H over the fuel line A NOTE D...

Page 36: ...ot run correctly after this adjustment proceed to the next step 4 7 2 4 7 2 Initial setting Throttle adjust screw L mixture needle and H mixture needle Tools Required P N G310 000050 Tachometer PET 304 P N X089 000094 Carburetor adjustment tool KIT D shaped tool L and Driver 2 5mm 1 Turn L and H mixture needles clockwise until lightly seated and then turn out both mixture nee dles following turns ...

Page 37: ...nt of L mixture needle to assure accurate tachometer readings 6 Before adjustment WOT engine speed should be 12 000 r min or less If engine speed is higher turn H mixture needle C counterclockwise until 12 000 r min is achieved Turn H mixture needle C clock wise in 1 8 turn increments with the engine at idle then squeeze throttle trigger and check WOT engine speed Adjust H mixture needle C to reac...

Page 38: ...ressure drops at step 3 or if pressure drops below standard figure at step 5 remove carburetor from the unit as step 8 9 and 10 8 Remove air cleaner cover and air filter 9 Remove two bolts D carburetor elbow E and carburetor F 10 Disconnect purge line G and throttle rod H from carburetor F 11 Submerge carburetor in suitable clean solvent to locate the leak by applying pressure approx 100 kPa 1 kgf...

Page 39: ...w one as required B A 4 10 Inspecting metering lever height 1 Remove carburetor 2 Remove four screws A metering diaphragm cover B metering diaphragm C and gasket D 3 Inspect metering lever E height by Metering lever gauge 897563 19830 F Metering lever height 1 65 mm 0 065 in lower than diaphragm seat G 4 If necessary gently bend metering lever E up or down to set metering lever to proper position ...

Page 40: ... follows Improper assembling of metering lever and spring Dirt between inlet needle valve and valve seat Worn inlet needle valve tip 3 Clean inlet needle valve seat using suitable clean solvent do not use metal tools 4 Reassemble inlet needle valve C spring B metering lever A and pivot pin NOTE Insure proper metering lever installation as follows 1 Spring is seated in its hole at chamber floor 2 S...

Page 41: ...turn H needle clockwise until lightly seated and remove inlet needle valve Otherwise main nozzle check valve and inlet needle valve spring may be damaged by the compressed air 9 Reassemble removed parts with particular at tention to each aspect 4 13 Replacing welch plug If engine does not run smoothly even after read justing carburetor and inspecting carburetor parts inspect low speed ports on car...

Page 42: ... throttle rod A to throttole lever B 2 Connect purge line C and joint D on carbure tor and install fuel inlet E to fuel line F 3 Pass purge line C through tab G as shown 4 Fasten carburetor and carburetor elbow H with two bolts J 5 Reassemble removed parts A B C E D F H J C G ...

Page 43: ...osen nut A and remove sprocket guard B NOTE If starter assembly is installed pull starter rope out about 20 cm 8 in and make a tempo rary knot to prevent starter damage when installing clutch assembly 2 Open cap cover C Disconnect spark plug cap and remove spark plug 3 Install clean rope D in spark plug hole E to stop crankshaft rotation NOTE Do not use piston stopper to avoid piston damage A B D ...

Page 44: ...lutch hub L and clutch shoes M If their clearances are large re place with new parts 8 Inspect circumuferences m1 and holes m2 hooked springs N for wear Replace with new parts as required 9 Inspect clutch plate H for wear Replace with new one as required 10 Inspect springs N for weakness or damage Replace with new parts as required 11 Inspect clutch drum J and it s sprocket j Re place with new one...

Page 45: ...ssembly is installed untie tempo rary knot holding starter grip tied in the first NOTE of 5 1 Inspecting clutch parts While holding starter grip turn clutch assembly counterclockwise untill it cannot rotate further piston touches piston stopper Release starter grip 3 Tighten clutch assembly Left hand thread with wrench G 4 Remove rope from spark plug hole and reinstall all removed parts OFF O F F ...

Page 46: ...Sprocket guard F Collar G Brake connector H Pin J Brake band K Spacer L Compression spring M Brake cover N Bolt M4 C D E G J A K L M 6 1 Replacing brake lever and torsion spring Disassembling 1 Remove starter assembly and sprocket guard from the unit 2 Remove bolt A chain catcher B and sprock et guard plate C A C B F H N ...

Page 47: ...om brake lever F 5 Check brake lever F if broken and torsion spring G if deformed or broken Replace with new part s if defective Assembling 6 Assemble torsion spring G as shown 7 Put hole f of brake lever F on boss g of en gine cover G 8 Assemble brake lever F pulling in direction of arrow 9 Tigten bolt D and insert collar E 10 Reassemble removed parts D F E G F F f g G F ...

Page 48: ... make brake connector engaging position NOTE Make sure that brake connector A is in engaging position before removing brake cover C otherwise compression spring may jump out 3 Remove bolt D and sprocket guard plate E 4 Loosen two bolts F securing brake cover C and remove brake cover C 5 If blocked with dirt or dust clean around brake parts And inspect all the brake parts for damage Replace with ne...

Page 49: ... guard as shown Note Make sure notch m of spacer M places as shown 9 Push compression spring N with driver or other suitable tool and install compression spring N in sprocket guard as shown 10 Install brake cover C and tighten two bolts F 11 Install sprocket guard plate E and tighten bolt D 12 Move brake connector A with ring wrench B or other suitable tool to released position as shown 13 Reassem...

Page 50: ...r washer M Worm gear N Oiler cover F G H A K L K B C E M N D 7 1 Inspecting oil cap and strainer 1 Remove oil cap 2 Inspect oil cap for cracks and gasket A for cuts or damage Replace worn or damaged parts as re quired 3 Replace connector B if damaged 4 Pull oil strainer B from oil tank using a wire hook C 5 Remove oil strainer B from oil line D and clean oil strainer in suitable solvent or replace...

Page 51: ...n chain oil in the tank is con sumed 1 Remove starter assembly 2 Push oil tank vent A into oil tank using suitable tool and take out vent A from oil tank 3 Clean oil tank vent A 4 Check that oil tank vent lips a are not hard or deformed Replace as required 4 Install oil tank vent A using suitable tool B as shown 5 Reassemble starter assembly a A A B ...

Page 52: ...e C it is recommended to use pipe joint V186 000020 F 6 Tighten oil cap and apply pressure approx 9 8 kPa 0 1kgf cm2 1 4psi 7 Pressure should not drop If the pressure drops leakage may occur at oil line oil cap oil cap gas ket oil tank vent or oil tank Inspect them and replace defective part s with new part s as re quired NOTE Remove oil strainer from oil line C before removing oil line C Refer to...

Page 53: ...ar A and circular washer B 3 Inspect worm gear A and circular washer B for damage wear or deformation Replace with new part s as required NOTE If worm gear A is dameged inspect gear of auto oiler assembly Refer to 7 5 Cleaning and replacing auto oiler assembly too 4 Apply lithium based grease to circular washer B and worm gear A Reinstall them 5 Reassemble removed parts Refer to 5 3 In stalling cl...

Page 54: ...ep 7 When plunger gear E can not be rotated go to step 14 7 Prepare ethanol F in container 8 Install new worm gear G to auto oiler B Set clutch drum H on worm gear G engaging sprocket h with two protrusions g of worm gear G 9 Dip auto oiler B in the ethanol F in container and rotate clutch drum H until plunger gear E rotates smoothly 10 Pull out spring pin J from adjust needle K with plier and pul...

Page 55: ... the plug K 18 Pull out spring pin J from adjuster needle K with plier 19 Pull out adjuster needle K and spring L from auto oiler body 20 Remove plunger gear E circular washer R spring S and circular washer T Circular washer R and T are not always come out because of stuck by chain oil 21 Clean plunger gear E oiler body oil channels and the otherparts using cotton tipped stick with ethanol or nail...

Page 56: ...elease finger from plunger gear E 28 Press adjuster needle K to the bottom orient ing the flat surface k1 as shown This position indicates maximum discharge volume of chain oil 29 Tap new spring pin J into hole k2 of adjuster needle K 30 Apply grease in plunger hole U Tap plug P into hole U with plastic mallet until plug P is flush with end face of oiler body 31 Connect auto oiler assembly B to oi...

Page 57: ...rankshaft H Needle bearing J Piston pin spacer K Piston pin A D F H K E J L L M N O P R R Q S T U V V W X Y Z L Snap ring M Piston N Piston ring O Cylinder P Cylinder piece Q Gasket Cylinder R Bolt M4 S Exhaust plate T Exhaust gasket U Muffler V Bolt M5 W Spark arrester screen X Screw M4 Y Engine cover Z Bolt M4 B B C G ...

Page 58: ...r several times to stabilize reading on compression gauge 6 If pressure is lower than approx 75 of standard compression pressure Refer to 1 2 Technical data inspect cylinder bore piston and piston ring for wear or damage 7 If pressure is more than approx 125 of stan dard compression pressure inspect cylinder combustion chamber and exhaust port piston crown and muffler for carbon deposits NOTE Comp...

Page 59: ...oden or plastic stick or brush or com pressed air as required WARNING DANGER Always wear eye protection when using compressed air for cleaning Otherwise eye damage can occur from flying particles 3 Inspect cylinder cooling fins C for blockage with dirt and or saw dust D Clean them with wooden or plastic stick or compressed air as re quired NOTE Remove ignition coil E if cylinder fins are hard to c...

Page 60: ... stick F if carbon is found NOTE When cleaning exhaust port always posi tion piston at Top Dead Center TDC to prevent carbon from entering cylinder Do not use metal tool and be careful not to scratch piston or cylin der NOTE Replace muffler gasket with new one when damaged or removing from muffler 4 Remove screw G and pull spark arrester screen H out from muffler B 5 Remove carbon deposits from sp...

Page 61: ...s E for carburetor 3 To seal exhaust port of cylinder cut pressure rubber plug 91041 F off as shown 4 Remove exhaust plate and muffler G with ex haust gasket H Refer to 8 3 Inspecting muffler and exhaust port 5 Set pressure rubber plug F to muffler G with exhaust gasket H as shown NOTE Make sure to cover exhaust port g of muffler with pressure rubber plug F 6 Gently tighten muffler bolts J1 and J2...

Page 62: ...soapy water to locate leakage 13 Then apply negative pressure approx 30 kPa 0 3 kgf cm2 4 4 psi by pressure tester and leave for 30 seconds 14 If the reading drops leakage may occur from oil seal Inspect oil seal for damage or wear 15 Remove pressure tester N and pressure con nector K Remove muffler G pressure rubber plug F pressure plate A or pressure rubber plug C K L M N K M 8 5 Removing engine...

Page 63: ...ard to remove cylinder B gently tap both crankshaft ends using plastic mallet C to remove crankcase assembly with crankshaft and piston assembly holding cylinder B 2 Inspect cylinder combustion chamber and clean with a plastic or wooden scraper if carbon is found NOTE Do not use metal tools or damage to cylin der wall may result 3 Inspect cylinder wall and replace with new one if plating is worn p...

Page 64: ... use square end of broken piston ring when cleaning piston ring groove otherwise piston ring groove might be damaged 4 Remove snap rings F from both sides of piston pin 5 Push piston pin G out from piston H NOTE If piston pin is tight use piston pin tool 897702 30131 J with adapter K stamped 8 on an end 6 Inspect piston pin needle bearing and piston pin spacers and replace if wear or discoloration...

Page 65: ...pusher adapter K stamped 8 12 Install new snap rings on both end of piston pin Make sure that they are properly seated in snap ring grooves NOTE Always use new snap rings 13 Install piston ring on piston 8 P Q H J K G Q 8 8 Replacing oil seal 1 Pry defective oil seal from crankcase NOTE Be careful not to damage crankshaft and oil seal housing NOTE Before removing flywheel side oil seal re move woo...

Page 66: ...n use puller Y089 000110 G prepared as follows 1 Drill two 6mm dia holes on puller Y089 000110 G as below 2 Three screws or bolts 91311 04075 H size M4x75mm lengh pitch 0 7mm 3 Three nuts 900500 00004 F size M4 pitch 0 7mm 4 Three circular washers 177214 03930 J size innner dia 4 5 x outer dia 16 5 x 1 0mm thick ness 7 Clean the inside of crankcase Replace with new one if damaged 8 Measure cranksh...

Page 67: ...ove ball bearing C Oil seal B remains in crankcase bore 5 Push out oil seal B with using oil seal tool 897726 09130 E Assembling 6 Set new ball bearing C with shaft A adapter F inner dia 15 mm outer dia 40 mm and boss D NOTE Set adapter F mating full flat side to ball bearing 7 Tighten shaft A with wrench to press ball bear ing into the crankcase half until flush 8 Check that bearing rotates smoot...

Page 68: ...OTE Make sure to match hole position D of crankcase gasket C and clutch side crankcase half B 4 Reassemble both crankcase halves together en suring that dowel pins b on clutch side crankcase half B are properly seated in holes on the other half 5 Tighten three bolts E diagonally to secure crankcase halves together and check crankshaft for smooth rotation NOTE If crankshaft doesn t rotate smoothly ...

Page 69: ...cavenging port b1 of cylinder as shown 3 Set new cylinder gasket C on cylinder B as notch c1 of gasket C aligns pulse hole b2 4 Install piston ring D on piston E ensuring the end gaps of piston ring are properly positioned around locating pin e1 as shown 5 Apply oil to piston ring D and internal wall of cylinder B 6 Install piston E in cylinder B with arrow e2 pointing as shown 7 Fasten four bolts...

Page 70: ...NTROL SYSTEM B A Front handle B Rear handle C Rear handle lid D Torsion spring E Throttle trigger F Throttle lockout G Throttle rod H Plug J Bolt M5 K Bolt M4 L Spring M Bolt M4 N Bolt M4 P Spring C D E F A G H J K M L N P Q R S T Q Bolt M4 R Spring S Bolt M4 T Bolt M4 ...

Page 71: ...e rod F from carburetor 7 Check throttle control parts and replace defec tive part s with new one as required Assembling 8 Insert throttle rod F to rear handle J and con nect throttle rod F to carburetor Refer to 4 14 Installing carburetor 9 Insert throttle rod F to hole of throttle triger E 10 Assemble throttle trigger E together with tor sion spring G on rear handle J 11 Insert torsion spring en...

Page 72: ...ndle C as shown and remove it from rear handle D 5 Remove bolt F and spring G Assembling 6 Install spring G to rear handle D and tighten screw F as shown NOTE Make sure to set spring G inside projec tion H 7 Install front handle C to rear handle D and turn as shown 8 Insert front side c of front handle C to rear handle D 9 Tighten bolt E and B NOTE If throttle rod is placed over the boss for bolt ...

Page 73: ...ting carburetor two plugs A collor B and C inserted intake bellows 6 Remove purge bulb and fuel line assembled rear handle Refer to 4 5 Replacing purge bulb and 4 6 Replacing fuel line and fuel return line 7 Remove bolt D and spring E1 8 Remove bolt F 9 Remove rear handle G and spring E2 from unit 10 Remove bolt H and spring J from rear han dle G 11 Check rear handle and springs and replace de fec...

Page 74: ...led parallel to line g3 of rear handle G If spring J is in an upward direction loosen bolts and retighten them 18 Insert two plugs A to rear handle G 19 Insert collar B and C to intake bellows L 20 Assemble front handle and spring Refer to 9 2 Replacing front handle and spring 21 Assemble purge bulb and fuel line Refer to 4 5 Replacing purge bulb and 4 6 Replacing fuel line and fuel return line 22...

Page 75: ...cing rear handle and springs continued 25 Insert rear part of rear handle lid N to hole g4 on rear handle G as shown 26 Assemble rear handle lid N as rib g5 on rear handle G enters into rear handle lid N 27 Assemble removed parts Section view N g4 G g5 N G g5 N G ...

Page 76: ... L Bolt M5 M Sprocket guard plate N Stud bolt C D E F A G H J K L M N 10 1 Replacing nut for fixing guide bar Disassembling 1 Pinch hook A with pliers B and remove hook A and nut C from sprocket guard D 2 Remove nut C from hook A 3 Check removed parts and replace defective parts with new one as required Assembling 4 Assemble nut C and hook A 5 Insert both ends a of hook A in holes d of sprocket gu...

Page 77: ...late B Tighten bolt A NOTE Make sure to hook tub h2 on sprocket gurad to hole b of sprocket guard plate B A B C D E F G H h1 A B h2 b 10 3 Replacing guide bar stud Disassembling 1 Remove chain catcher and sprocket guard plate from engine cover 2 Install two nuts on defective stud A and tighten them against each other 3 Turn nut B counterclockwise to remove stud NOTE If it is hard to remove or brok...

Page 78: ...tion is excessive Engine does not stop Oiler does not function Saw chain does not cut well INSPECTING Starter system Starter drum rope Ignition system Sparks Spark plug Spark plug cap coil Ignition switch Ignition coil Pole shoe air gaps Flywheel 2 2 3 2 3 3 3 4 3 5 3 7 3 8 3 9 Continued 15 Inspecting first 14 13 12 11 10 09 08 07 06 05 04 03 02 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Flyw...

Page 79: ... 8 3 1 2 8 1 8 4 1 5 8 6 8 9 1 5 8 7 Fuel tank line vent Purge bulb 4 3 to 4 6 INSPECTING 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 REFERENCES Carburetor diaphragms 4 12 Crankcase pulse passage 4 9 Throttle trigger 4 14 9 1 Fuel octane freshness purity 4 7 1 Others Chain brake Springs Saw chain 6 1 to 6 2 9 2 to 9 3 Replace Sharpen 15 14 13 12 11 10 ...

Page 80: ...lter 4 1 Carburettor 4 8 4 14 Clutch drum 5 1 5 3 Ignition switch 6 1 Brake lever Rear handle lid 9 1 8 9 8 11 Crankshaft Spark plug 3 2 3 3 Clutch ASY 5 1 to 5 3 Sprocket guard Throttle control parts 9 1 7 4 Worm gear Flywheel Chain brake parts Engine block 8 5 Cylinder 8 6 3 7 Ignition coil 8 9 8 11 Crankcase 8 10 Ball bearing Sprocket guard plate Chain catcher 6 1 6 2 10 1 Chain tensioner 9 3 R...

Page 81: ...3 5 3 6 Fuel tank Clean inside 4 3 Muffler and exhaust port Clean 8 3 Starter system Inspect Repair 2 1 to 2 4 Oil tank Clean inside Oil strainer Clean Replace 7 1 Sprocket Inspect Replace 1 5 5 1 Guide bar Inspect Clean Chain brake Inspect Repair 6 1 to 6 3 Daily Inspecting in every services IMPORTANT Service intervals shown above are maximum Actual use and your experience will determine the freq...

Page 82: ...ead 16 Ignition coil 4 13 14 22 23 76 78 Ignition switch 4 13 14 17 to 21 76 78 Ignition system 2 3 13 Ignition timing 3 Inlet needle valve 38 77 Intake bellows 4 37 60 78 Key flywheel 13 23 24 76 L mixture needle 3 34 35 Maintenance guide 76 to 79 Metering diaphragm 39 Metering lever 3 6 37 38 Metering lever height 3 6 37 77 Muffler 2 4 55 58 77 to 79 Needle bearing clutch 4 41 to 43 76 Needle be...

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Page 84: ...Published by YAMABIKO Corp Tokyo Japan 1604 ...