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SERVICE INFORMATION

HCA-2500

6

a

20

20

40

40

60

60

80

80

120

120

140

140

160

160

18

0

180

20

20

100

100

91019 

Ignition Air 

Gap 

Gauge

#.014 = .35mm

P/N 91004

 Key    Part Number

Description

  Used for:

1

897801-33330

Tachometer PET-1000 Measuring engine speed to adjust carburettor

2

363018-00310

Washer

Installing crankcase oil seal of starter side

3

433019-12330

Flange nut

Removing magneto rotor (flywheel)

4

895612-79920

L-hex wrench (3 mm)

Removing and installing hex. socket bolts (M4)

5

895610-79920

L-hex wrench (4 mm)

Removing and installing hex. socket bolts (M5)

6

897701-06030

Bearing wedge

Removing ball bearings on crankshaft

7

897701-14732

Bearing tool

Removing and installing crankcase bearings

8

897702-30131

Piston pin tool

Removing and installing piston pin 

(Use 8 mm dia. adapter)

9

897705-11520

Bearing tool

Removing and installing con-rod small end needle bearing

10

897712-04630

2-pin wrench

Removing and installing pawl carrier

11

897714-22830

Oil seal tool

Installing ball bearing in gear case

12

897714-24330

Oil seal tool

Installing crankcase oil seals

13

897726-09130

Oil seal tool

Removing clutch drum and installing clutch drum ball bearing

  14           91004           Module air gap gauge    Adjusting pole shoe air gaps
  15    897800-79931

Spark tester

Checking ignition system

16

897803-30132

Pressure tester

Checking carburettor and crankcase leakages

17

897835-16131

Pressure connector

Checking crankcase and cylinder leakages

18

900100-08008

Bolt

Removing magneto rotor (flywheel)

19

       91007

Compression gauge

Measuring cylinder compression

20

       91019

Limiter cap tool

Removing and installing limiter cap

1-6 Special tools

1

: a=3mm

: a=4mm

2

3

6

7

8

9

10

11

12

14

15

16

18

17

20

19

13

Summary of Contents for HCA-2500

Page 1: ...sed on the latest products information available at the time of publication 1 CONTENTS page 1 SERVICE INFORMATION 2 1 1 Specification 2 1 2 Technical data 3 1 3 Torque limits 4 1 4 Special repairing m...

Page 2: ...Automatic rewind Rope diameter x length mm in 3 0 x 1000 0 12 x 39 4 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Petrol Minimum 89 octane petrol RON Two stroke air cooled engine oil ISO L...

Page 3: ...coil resistance 200 400 Secondary coil resistance k 1 3 1 8 Pole shoe air gaps mm in 0 30 0 40 0 012 0 016 Ignition timing at 3000 r min BTDC 29 at 8000 r min BTDC 28 at 9000 r min BTDC 12 Carburettor...

Page 4: ...ne Crankcase M 5 75 85 7 5 8 5 65 75 Cylinder M 5 75 85 7 5 8 5 65 75 Cylinder cover M 4 35 45 3 5 4 5 30 40 Muffler M 5 55 65 5 5 6 5 50 55 Top guard M 5 25 35 2 5 3 5 22 30 Regular bolt nut and scre...

Page 5: ...inder bore When plating is worn and aluminium can be seen B Piston outer diameter Min 33 91 1 335 C Piston pin bore Max 8 030 0 3161 D Piston ring groove Max 1 6 0 063 E Piston ring side clearance Max...

Page 6: ...Removing and installing piston pin Use 8 mm dia adapter 9 897705 11520 Bearing tool Removing and installing con rod small end needle bearing 10 897712 04630 2 pin wrench Removing and installing pawl c...

Page 7: ...roceed to the next step 2 2 C After adjusting carburettor according to the steps 2 2 and 2 3 the limiter cap s must be installed on L and or H mixture needle s to comply with Emission Directive 2 2 Pr...

Page 8: ...p tool 91019 into centre hole of previous limiter cap to pull out completely 5 Turn idle adjust screw anticlockwise and set the screw until the tip to just contact throttle plate Then turn idle adjust...

Page 9: ...ed in the range of 2 600 to 2 800 r min NOTE Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings 5 Turn H...

Page 10: ...on Directive 9 Start engine again and make sure engine runs at idle speed in the range of 2 400 to 3 200 r min and at WOT engine speed in the range of 9 000 to 10 500 r min Also make sure blade would...

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