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Echo CS-370ES Service Manual Download Page 51

49

ENGINE

CS-370ES
CS-420ES

7-10 Installing piston and piston ring

1. Lubricate needle bearing with 2-stroke engine oil.

2. Set needle bearing and piston pin spacers (A) on
small end of connecting rod (B) as shown.

NOTE: Place piston pin spacers on connecting rod
with dents (a) inside as shown.

NOTE: Place piston over connecting rod with piston
arrow mark (C) pointing as shown.

3. Insert pin guide tool (D) stamped “9”, through
piston, piston pin spacers and needle bearing set
at step 2.

4. Insert piston pin in piston pushing out pin guide
tool until the pin end comes up to snap ring groove
(E).

NOTE: If piston pin is tight, use piston pin tool
897702-30131 with pusher adapter stamped “8”.

5. 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.

6. Install piston ring on piston.

D

C

a

A

B

E

Summary of Contents for CS-370ES

Page 1: ...Ord No 401 29 ...

Page 2: ...escribes problems testing remedies and references We recommend you make use of Operator s Manual and Parts Catalog together with this manual when servicing We are constantly working on technical improvement of our products For this reason technical data equipment and design are subject to change without notice All specifications illustrations and directions in this manual are based on the latest p...

Page 3: ...ing lever height 32 4 12 Inspecting inlet needle valve 32 4 13 Replacing Welch plug 33 4 14 Installing diaphragm 33 4 15 Installing carburetor 34 5 CLUTCH SYSTEM 35 5 1 Inspecting clutch parts 35 5 2 Replacing clutch parts 36 5 3 Installing clutch assembly 36 6 SAW CHAIN LUBRICATION SYSTEM 37 6 1 Inspecting oil cap and strainer 37 6 2 Inspecting oil line 38 6 3 Inspecting oil tank vent 38 6 4 Repl...

Page 4: ...tem Spark plug BPMR8Y Starter Type ES effortless start Rope diameter x length mm in 3 0 x 950 0 12 x 37 4 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Gasoline Minimum 89 octane gasoline Two stroke air cooled engine oil ISO L EGD ISO CD13738 JASO M345 FC FD Tank capacity L U S fl oz 0 41 13 9 Clutch Type Centrifugal 3 shoe slide with 3 tension spring Guide bar Saw chain lubrication type...

Page 5: ... Minimum secondary voltage at 1000 rpm kV 15 Secondary coil resistance kΩ 1 5 2 2 Pole shoe air gaps mm in 0 3 0 4 0 012 0 016 Ignition timing at 3 000 rpm BTDC 10 10 at 8 000 rpm BTDC 32 32 at 10 000 rpm BTDC 34 34 at 12 000 rpm BTDC 15 15 Carburetor Idle adjust screw initial setting turns in 1 5 8 1 3 8 L mixture needle initial setting turns back 1 1 4 1 3 8 H mixture needle initial setting turn...

Page 6: ... M5 30 50 3 5 26 45 M4 35 50 3 5 5 30 45 Handle lid M4 10 20 1 2 9 17 Brake lever Hand guard M5 10 20 1 2 9 17 M4 45 65 4 5 6 5 40 55 Sprocket guard plate M4 10 20 1 2 9 17 Chain catcher M5 45 60 4 5 6 40 52 Guide bar M8 200 230 20 23 175 200 Regular bolt nut M3 6 10 0 6 1 5 9 and screw M4 15 25 1 5 2 5 13 22 M5 25 45 2 5 4 5 22 40 M6 45 75 4 5 7 5 40 65 1 4 Special repairing materials Material Lo...

Page 7: ... 0 063 E Piston ring side clearance Max 0 1 0 004 F Piston pin outer diameter Min 8 98 0 3535 G Piston ring width Min 1 45 0 057 H Piston ring end gap Max 0 5 0 02 K Con rod small end bore Max 12 025 0 4734 L Crankshaft runout Max 0 05 0 002 M Sprocket bore Max 13 07 0 5146 N Clutch drum bore Max 71 5 2 81 P Sprocket wear limit Max 0 5 0 02 1 5 Service Limits 5K173 5K280 5K174 5K190 5K016 5K042 5K...

Page 8: ...eight on carburetor 10 897826 16131 Pressure rubber plug Testing crankcase and cylinder sealings 11 897831 16131 Pressure rubber plug Testing crankcase and cylinder sealings 12 897726 09130 Oil seal tool Installing oil seals 13 897603 23030 PTO shaft puller Removing auto oiler cap 14 897800 79931 Spark tester Checking ignition system 15 897803 30133 Pressure tester Testing carburettor and crankcas...

Page 9: ...kshaft will be rotated 7 Power spring absorbs compression resistance of cylinder and snatch back of engine during starting action 8 When starter rope is released rope reel D is returned together with power spring E and pawl catcher F by rewind spring tension 9 After engine starts starter pawls pivot outward by centrifugal force and disengage from pawl catcher F 2 STARTER SYSTEM ES starter A Starte...

Page 10: ...ction and take care when re moving starter drum because rewind spring may unwind suddenly and cause injury to eyes and body C D E G A 2 1 Disassembling starter assembly 1 Remove four bolts securing recoil starter assembly Remove recoil starter assembly from unit 2 Pull out starter rope about 30 centimeters 12 in and hold rope reel A Loop excess rope in rope reel notch B as shown 3 Rotate rope reel...

Page 11: ...stalling a new starter rope singe both ends of the rope to prevent fraying 4 Make a knot C at end of starter rope and pass the rope through hole of rope reel then press the knot C into reel well as shown 5 Pass the other end of starter rope through rope guide on starter case then pass starter rope through starter grip and make a knot as shown B A ...

Page 12: ... hole C with post D Hook E of rewind spring should contact with post of starter case 3 Assemble rope reel F engaging hook f of rope reel with hook E of rewind spring 2 3 Assembling starter 1 If rewind spring B is unwound from rewind spring case A wind the spring inside case as shown A B E D C f F E ...

Page 13: ...spring hook J into pawl catcher hole I F 2 3 Assembling starter continued 4 Check for proper engagement of rewind spring and rope reel by turning rope reel F clockwise and counterclockwise 5 Install power spring assembling hook G of power spring into rope reel cutout H G H J I ...

Page 14: ...r rope hooked at notch Q as shown Hold rope reel to prevent it from rewinding and pull out starter grip to take the rope slack P Q 2 3 Assembling starter continued 9 Pull starter several times to check rewind spring tension If starter is not rewinding fully rotate rope reel one more turn clockwise following above step 8 10 Pull out starter rope all the way and check that rope reel can be rotated a...

Page 15: ...g on starter pawl The bolt is pre coated with sealant on the thread If the coat is peeled off apply thread locating sealant Loctite 242 ThreeBond 1324 or equivalent 4 Using fine wire or hook tool F place hook of torsion spring on pawl G as shown 5 Make sure pawl can move smoothly If it does not move smoothly check parts for correct installation E G F 2 4 Replacing starter pawl continued ...

Page 16: ... B Ignition coil C Spark plug D Spark plug cap coil E Spark plug cap F High tension lead G Primary lead H Ground lead I Spacer J Switch bracket K Throttle rod L Lead terminal M Ignition switch N Choke knob O Choke grommet P Purge bulb A B C D F E G H K I L M N O J P ...

Page 17: ...K Not OK S T OK OK Replace ignition coil Leads connections Not OK OK OK Not OK S T Repair Replace Not OK Remedy Inspect Not OK Flywheel key OK R T End Not OK Flywheel magnet Replace Not OK R T Not OK OK OK Replace ignition coil and or inspect other systems Replace flywheel OK OK Adjust pole shoe air gaps Inspect flywheel magnet at the same time Go to A if OK S T Not OK A S T Spark test R T Running...

Page 18: ...ue with further inspection DANGER Do not test near spark plug hole without spark plug installed otherwise there is a chance to ignite fuel mixture inside cylinder and cause serious personal injury Do not touch metal parts of spark tester while performing the test to avoid receiving electrical shock DANGER Do not check spark in area where gasoline is spilled or flammable gases may exist 3 3 Inspect...

Page 19: ...emove air cleaner bracket G and air filter Disconnect primary lead and ground lead from ignition switch 2 Disconnect throttle rod B from carburetor Refer to 9 4 Replacing throttle trigger and remove switch bracket A from engine cover 3 Loosen nut C and remove ignition switch D and switch plate E from switch bracket A 4 Inspect switch plate E and switch bracket A If damaged replace with new parts 5...

Page 20: ... 5 If the reading at step 3 or 4 is not in the range of 1 5 to 2 2 kΩ replace with a new ignition coil Go to 3 7 Replacing spark plug cap and coil 3 7 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 removal from high tension lead B 3 Pull spark plug cap away from high tension lead 4 Inspect spark plug cap coil C for corr...

Page 21: ... two bolts C loosely After adjusting air gap using Module air gap gauge 91004 Refer to 3 9 Setting pole shoe air gauge tighten bolts C to specified torque 7 Connect spark plug cap D to spark plug and reinstall starter assembly and cylinder cover in place 3 9 Setting pole shoe air gaps 1 Insert Module air gap gauge 91004 A or 0 3 0 4 mm 0 012 0 016 in thick feeler gauge between flywheel and ignitio...

Page 22: ...power tool Otherwise piston damage may occur 4 Remove starter pawls Then set puller 897501 03938 B on flywheel as shown 5 Tighten 2 nuts on the puller alternately to remove flywheel 6 Inspect woodruff key for damage or shearing Replace as required 7 Wipe off oil from taper part of crankshaft before assembling flywheel 8 Install woodruff key into key groove 9 Reinstall starter pawls Refer to 2 4 Re...

Page 23: ...D Intake insulator E Fuel inlet line F Purge bulb G Air cleaner bracket H Air filter I Carburetor elbow J Fuel tank vent K Fuel tank vent line L Fuel tank M Fuel cap N O ring O Connector P Fuel line grommet Q Fuel line R Fuel return line S Fuel strainer A C D E F I H G B J K L O N M Q P R S ...

Page 24: ...rt or dust clean air filter with compressed air NOTE Blow with compressed air from inside of filter If blowing with compressed air from outside of air filter filter paper may be clogged with particles NOTE Do not wash air filter by solvent or gasoline to avoid damaging it 4 Replace air filter with new one if heavily soiled or damaged 4 2 Inspecting fuel cap and strainer 1 Remove fuel cap 2 Inspect...

Page 25: ...itch bracket A from engine cover Refer to 3 5 Replacing ignition switch 2 Remove fuel return line B and fuel inlet line C from purge bulb 3 Pinch hooks D of purge bulb with needlenose pliers and remove purge bulb 4 Install new purge bulb 5 Connect fuel inlet line C to shorter fitting F 6 Connect fuel return line B to the other fitting E A B D C B F E C ...

Page 26: ...dlenose pliers as shown NOTE Wrap the ends of needlenose pliers with tape or cover with soft pipes to prevent damage to fuel line 6 Apply pressure approx 49 kPa 0 5 kgf cm2 7 psi 7 If pressure drops replace fuel line 8 Put fuel strainer in fuel tank and fasten fuel cap securely 9 Apply pressure approx 9 8 kPa 0 1 kgf cm2 1 4 psi 10 Pressure should not drop If the pressure drops leakage may occur f...

Page 27: ...1 0 4 kgf cm2 1 4 5 7 psi 3 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 assembly Damage to valves will occur 4 Remove cap C of tank vent and clean sponge D 5 Cut pipe 363024 04010 E 7x11x170 mm and 382011 01110 F 9x13x350 mm in approx 30 mm 1 1 4 in length and connect them to pressure tester as shown Conne...

Page 28: ...ne remove fuel cap and remove fuel strainer D and clip E from fuel line A 4 Install fuel line F and fuel return line G on the grommet H as shown 5 Install assembled grommet in fuel tank NOTE Assemble grommet with fuel return line G oriented towards rear handle 6 Pull out fuel line from fuel tank and install clip and fuel strainer to fuel line 7 Install engine cover and engine block on rear handle ...

Page 29: ...r two minutes alternating rpm between WOT and idle every 5 seconds Turn L and H mixture needles full anticlockwise Adjust idle speed screw to 2 650 250 rpm If engine does not run correctly after this adjustment proceed to the next step 4 7 2 IMPORTANT After adjusting carburetor according to the steps 4 7 2 and 4 7 3 the limiter cap s must be installed on L and H mixture needle s to comply with Emi...

Page 30: ...ew threaded end of limiter cap removal tool 91019 into center hole of the other limiter cap anticlockwise until the limiter cap is removed from the mixture needle completely Remove the limiter cap from limiter cap removal tool turning clockwise and screw thread of limiter cap removal tool 91019 into center hole of previous limiter cap to pull out completely 5 Turn L and H mixture needles clockwise...

Page 31: ... 1 8 turn increments with the engine at idle then squeeze throttle trigger and check WOT engine speed The final WOT engine speed should fall within 11 700 to 12 300 rpm CS 370ES 12 400 to 12 800 rpm CS 420ES range 7 After adjusting carburetor screw new limiter cap on the limiter cap removal tool 91019 C anticlockwise approx 2 turns as shown and put the limiter caps on L and H mixture needles respe...

Page 32: ...sition 1 Air cleaner cover on CS 370ES and CS 420ES has plug 2 The picture shows normal position of the plug A 3 Remove the plug from air cleaner cover to open the warm air intake and introduce warm air from cylinder side to carburetor room And place the plug in holder B on air cleaner cover to avoid losing as shown NOTE Replace the plug to normal position when the temperature is over 10 ºC to avo...

Page 33: ...disconnect throttle rod from carburetor Refer to 9 4 Replacing throttle trigger and remove switch bracket Disconnect choke rod from carburetor Remove carburetor from the unit 7 Submerge carburetor in suitable clean solvent to locate the leak by applying pressure approx 98 kPa 1 kgf cm2 14 psi 8 If air bubbles come out between pump cover and carburetor body B inspect pump diaphragm pump gasket and ...

Page 34: ... Remove metering lever A and pivot pin Remove spring B and inlet needle valve C 2 Inspect inlet needle valve if worn or sticky Clean or replace as required NOTE Causes of fuel flooding from carburetor to cylinder are as 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 c...

Page 35: ...using welch plug installer C 5 Install all removed parts to carburetor body 4 14 Inspecting diaphragm 1 Inspect metering diaphragm A for hardening distortion or pin hole Replace as required 2 Remove pump cover F pump diaphragm D and pump gasket E 3 Inspect pump diaphragm D and replace if hardened or curled at valve tabs 4 Inspect metering gasket B and pump gasket E and replace if defective 5 Inspe...

Page 36: ...el inlet line F under fuel line B and fuel return line G as shown 4 Connect choke rod H with carburetor passing fuel return line G as shown 5 Connect throttle rod J with carburetor passing fuel inlet line F as shown Set switch bracket in place Refer to 3 5 Replacing ignition switch 6 Connect fuel inlet line F and fuel return line G with fittings of purge bulb referring to 4 3 Replacing purge bulb ...

Page 37: ...er 5 Loosen clutch assembly Left hand thread rotating clockwise with clutch tool 897505 16133 E and remove it NOTE Do not use power tools Otherwise piston damage may occur 6 Remove clutch drum clutch plate needle bearing collar worm gear and circular washer 7 Inspect clutch shoes for wear and spring for weak ness or damage Replace clutch parts as required 8 Inspect clutch drum and sprocket Replace...

Page 38: ...emporary knot in the first NOTE of 5 1 Inspecting clutch parts Hold starter grip as the rope is pulled out 3 Turn clutch assembly counterclockwise using clutch tool 897505 16133 H by hand until it can not be turned further 4 Tighten clutch assembly Left hand thread with clutch tool 897505 16133 NOTE If starter assembly is installed release starter grip to return starter rope into starter assembly ...

Page 39: ...damaged parts as required 3 Pull oil strainer B from oil tank using a wire hook C 4 Remove oil strainer B from oil line D and clean oil strainer in suitable solvent or replace if damaged A Oil outlet line B Auto oiler assembly C Oil tank D Oil tank vent E Oil strainer F Grommet G Oil line H Oil cap I O ling J Connector 6 SAW CHAIN LUBRICATION SYSTEM A A B C D E G H I J F B C D B ...

Page 40: ...ssure should not drop If the pressure drops leakage may occur at oil cap oil cap O ring mating surface of oil tank oil line grommet or oil tank vent Inspect them and replace defective part s with new parts as required 6 3 Inspecting oil tank vent NOTE Oil tank vent prevents a vacuum from forming in oil tank when chain oil in the tank is consumed 1 Remove oil tank vent A using paper clip and clean ...

Page 41: ...er assembly 7 Insert new oil line to grommet install clip A on the end of oil line as shown NOTE Apply sealant Loctite 242 Threebond 1324 or equivalent between grommet and oil line to prevent oil line movement 8 Insert oil line B and grommet C in engine cover and install as shown NOTE Oil strainer E will be installed at step 11 NOTE If oil line is not positioned correctly chain oil may not be supp...

Page 42: ...haft puller 897603 23030 C as shown 4 Hold auto oiler body by one hand Hold puller shaft end c by another hand Hold auto oiler body upper side and shake the weight D up and down several times to remove the plug A 5 Pull out spring pin E from adjuster needle F with pliers 6 Pull out adjuster needle F from auto oiler body 7 Remove plunger G and spring H 8 Check plunger if worn out or broken and spri...

Page 43: ...steel wire such as paper clip through the opening as shown 3 Bend steel wire and lift up V ring from the groove 4 Slowly rotate plunger while pulling V ring all the way out 5 Oil inner wall a of new V ring Hook V ring with steel wire as shown 6 Put V ring on the end B of plunger NOTE Lips C of V ring should face gear 7 Move V ring into the groove while carefully rotating plunger A C B a ...

Page 44: ... Push in plunger with small screwdriver F and hold plunger in place with finger through the center hole G of auto oiler body Remove screwdriver F 4 Install adjuster needle H with spring J into oiler body 5 Press adjuster needle H to the bottom orienting the flat surface h as shown 6 Tap in new spring pin K into hole L of adjuster needle until spring pin bottoms 7 Apply grease in plunger hole Tap p...

Page 45: ...pper crankcase B Crankcase Lower crankcase C Crankshaft assembly D Ball bearing E Oil seal F Engine cover G Piston ring H Snap ring I Piston J Piston pin K Needle bearing L Piston pin spacer M Intake bellows N Intake gasket K L F E B M N C D I H A G J ...

Page 46: ...combustion chamber and exhaust port piston crown and muffler for carbon deposits NOTE Compression pressure varies with volume of compression gauge tip occupying cylinder combustion chamber If gauge tip volume is considerably different from spark plug volume it is recommended to measure and note compression pressure of brand new engines as standard pressure in advance 7 2 Cleaning cooling air passa...

Page 47: ... screen B from muffler 4 Remove carbon deposits from spark arrestor screen and muffler lid If screen has heavy deposits replace with a new screen 5 Reinstall muffler with new gasket and cylinder cover 7 4 Testing crankcase and cylinder sealing 1 Remove cylinder cover 2 Remove air filter bracket and air filter Disconnect fuel return line and fuel inlet line from purge bulb Refer to 4 3 Replacing pu...

Page 48: ...m pulse pipe and pressure rubber plugs A C from intake insulator and exhaust port 7 5 Removing engine block 1 Remove starter assembly cylinder cover sprocket guard and front handle from unit 2 Remove air filter bracket and air filter Disconnect fuel return line and fuel inlet line from purge bulb Refer to 4 3 Replacing purge bulb Remove switch bracket Refer to 3 5 Replacing ignition switch Disconn...

Page 49: ... 7 Inspect cylinder wall and replace crankcase as a set if plating is worn peeled away scored or exposing cylinder base metal 7 7 Inspecting piston and piston ring 1 Inspect piston ring and replace it if broken or scored or if it exceeds service limits Refer to 1 5 2 Inspect piston crown top land ring groove and skirt Clean them with fine sand paper oil stone or ring groove cleaning tool if carbon...

Page 50: ...pletely seated against crankshaft counterweights NOTE Preheat ball bearing using heating gun heat lamp or suitable heater for easier installation 4 Install oil seals onto both ends of crankshaft insuring proper direction of oil seal 7 8 Inspecting crankcase and crankshaft 1 Clean crankcase Replace as a set of cylinder and crankcase if damaged 2 Completely remove sealant residue on mating surfaces ...

Page 51: ...h piston arrow mark C pointing as shown 3 Insert pin guide tool D stamped 9 through piston piston pin spacers and needle bearing set at step 2 4 Insert piston pin in piston pushing out pin guide tool until the pin end comes up to snap ring groove E NOTE If piston pin is tight use piston pin tool 897702 30131 with pusher adapter stamped 8 5 Install new snap rings on both end of piston pin Make sure...

Page 52: ...void breakage of piston ring and scoring cylinder bore 4 Make sure that rims of oil seal are properly seated in the grooves of cylinder upper crankcase 5 Apply liquid gasket Loctite 515 Parts No 890610 00051 or equivalent on seams C of lower crankcase half 6 Apply adhesive Loctite 675 or equivalent on bearing bores D of lower crankcase half as shown 7 Set crankcase halves as shown Fasten 4 bolts E...

Page 53: ...all the flange F of intake bellows in hole G of intake insulator 4 Apply 2 stroke engine oil to the both sides and bottom h of intake insulator cushion H 5 Mount engine block on engine cover J while installing intake insulator cushion H with intake insulator K into the grooves L of engine cover 6 Tighten 4 bolts M at unit bottom to secure engine block to engine cover Install all other removed part...

Page 54: ...osition NOTE Make sure that lever B is in engaging position before removing brake cover C otherwise compression spring may jump out 3 Loosen three screws securing brake cover C and remove brake cover 4 Inspect all the brake parts for damage Replace them as required 8 CHAIN BRAKE SYSTEM A M N B C J F G E L H K D A Brake lever B Screw C Collar D Collar E Bolt F Torsion spring G Brake cover H Brake c...

Page 55: ...Install roller E through brake band hole F 2 Set the above assembly into sprocket guard as shown Slide in compression spring G to the end H of brake connector as shown 3 Install compression spring G into sprocket guard using flat blade screwdriver as shown 4 Apply molybdenum grease on whole of compression spring G and other friction parts 5 Install brake cover J G H A B C D E F b J G ...

Page 56: ...AR HANDLE AND CONTROL SYSTEM 9 REAR HANDLE AND CONTROL SYSTEM A Rear handle B Torsion spring C Spring pin D Throttle trigger E Throttle lockout F Rear handle cover G Throttle latch CS 370 H Cushion I Collar H A F D C I E B G ...

Page 57: ...nstalling throttle latch do not exceed 6 10 kgf cm 0 6 1 0 N m 5 9 in lbf of torque If torque exceeds this standard throttle latch damage may occur 9 2 Replacing cushions 1 Remove cylinder cover from the unit 2 Remove switch bracket Refer to 3 5 Replacing ignition switch Remove air filter bracket and air filter Disconnect fuel lines from carburetor and remove carburetor from the unit 3 Remove cush...

Page 58: ...se on outer surfaces b then push in cushion as shown 9 Remove cushion D with needlenose pliers cutting off glued part d with cutter 10 Push in cushion D without applying grease oil 11 Apply adhesive Loctite 424 ThreeBond 1741 or equivalent on the part d between cushion and engine cover NOTE If grease oil is applied on cushion adhesive force may be weak B d D b D d ...

Page 59: ...3 5 Replacing ignition switch and related parts 9 3 Replacing throttle trigger 1 Loosen screw A and remove rear handle cover B 2 Inspect rear handle cover B and throttle lockout C for cracking or wear If damaged replace it as required 3 Push out spring pin D from rear handle using spring pin tool 897724 01361 E NOTE Spring pin will stop before completely coming off from rear handle because of effe...

Page 60: ...torsion spring B in place and insert spring pin tool 897724 01361 E from the other side of handle through the hole of throttle trigger 3 Lightly tap in spring pin C pushing out spring pin tool E 7 Hook the inside notch f of rear handle cover F on the tab G of rear handle 8 Install rear handle cover F on rear handle H setting torsion spring J with throttle lockout K as shown 9 Tighten screw L to se...

Page 61: ...ING SYSTEM CS 370ES CS 420ES 10 GUIDE BAR MOUNTING SYSTEM A Inner sprocket guard plate B Outer sprocket guard plate C Tensioner screw D Chain tensioner E Bevel gear F Bevel gear G Collar H Guide bar stud A B C D E F G H ...

Page 62: ...6 Set bevel gear D in collar F and insert ten sioner screw B with chain tensioner C in bevel gear with collar F 7 Install sub assembled tensioner screw in slot G of sprocket guard confirming engagement of bevel gear D and E 8 Reinstall outer sprocket guard plate A 10 2 Replacing guide bar stud 1 Remove oil cap and empty oil in tank 2 Remove inner sprocket guard plate 3 Push defective guide bar stu...

Page 63: ... D Thread M8 nut E clockwise onto stud Turn nut clockwise to pull stud through the engine housing mounting hole The square head of the stud should seat against the oil tank wall parallel with inner ribs 5 Look into oil tank and check if square head F of the stud is properly seated inside engine cover If not install two nuts to the stud and secure them against each other 6 Turn nut G counterclockwi...

Page 64: ...4 4 Muffler and exhaust port Clean 7 3 Starter system Inspect Repair 2 2 Oil tank Clean inside Oil strainer Clean Replace 6 1 Sprocket Inspect Replace 1 5 5 1 Guide bar Inspect Clean Chain brake Inspect Repair 8 1 8 2 Daily Inspecting in every services IMPORTANT Service intervals shown above are maximum Actual use and your experience will determine the frequency of required maintenance Retighten t...

Page 65: ...remely noisy Fuel consumption is excessive Vibration 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 7 3 4 3 6 3 8 3 9 3 10 Continued 15 Inspecting first 14 13 12 11 10 09 08 07 06 05 04 03 02...

Page 66: ...7 Fuel tank line vent 4 4 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 13 Crankcase pulse passage 4 9 Throttle trigger 9 3 Clutch system Clutch shoes spring bearing Clutch drum 5 1 to 5 3 5 1 5 3 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Others Chain brake Cushions Saw chain 8 1 8 2 9 2 Replace Sha...

Page 67: ... 9 C b lutch side all bearing 7 9 Crankcase 7 6 7 7 7 11 Cylinder Piston ring Carburetor 4 8 to 4 14 Spark plug 3 3 Air filter 4 1 Exhaust muffler 7 3 e Clutch sid oil seal 7 9 Flywheel 3 10 Engine block Engine cover 7 5 Auto oiler 6 4 to 6 7 Sprocket guard 8 1 10 1 Clutch assembly 5 1 to 5 3 Cylinder cover Cushions 9 2 Rear handle 9 2 Cleaner lid Switch blacket 3 5 Clutch drum 5 1 5 3 Worm gear ...

Page 68: ...ition timing 3 Inlet needle valve 31 to 33 64 Intake bellows 4 43 47 51 65 Intake insulator 45 to 47 51 Key flywheel 15 20 63 Limiter cap 6 27 to 29 Liquid gasket 4 50 L mixture needle 3 27 to 29 Maintenance guide 62 to 65 Metering diaphragm 32 33 64 Metering lever 3 6 32 33 60 Metering lever height 3 6 31 32 64 Minimum secondary voltage 3 Muffler 4 27 45 to 47 51 62 64 65 Needle bearing clutch 4 ...

Page 69: ...TOKYO JAPAN Printed in Japan 0712 ...

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