Makita DCS460 Repair Manual Download Page 1 | Manualshive

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REPAIR MANUAL

DCS460

DCS510

DCS5121

EA5000P53G

PS-460

PS-510

PS-5105

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Summary of Contents for DCS460

Page 1: ...REPAIR MANUAL DCS460 DCS510 DCS5121 EA5000P53G PS 460 PS 510 PS 5105...

Page 2: ...um Rim sprocket 9 03 Chain brake Guide bar bolt 10 11 04 Clutch 12 13 05 Oil pump 14 06 Starter 15 07 Ignition system trouble shooting 16 07 Ignition system 17 18 08 Carburetor 19 20 09 Vibration damp...

Page 3: ...tor ZAMA membrane carburetor Ignition system Typ condenser ignition system electronic condenser ignition system Spark plug Typ NGK BPMR 7A Electrode gap mm 0 5 or spark plug Typ BOSCH WSR 6F Fuel cons...

Page 4: ...starter broken broken parts inside the engine Engine speed gets stuck Multiple systems Engine speed about 4500 6000 rpm Carburetor too lean Bleed air at cylinder and or rubber induction piece Fuel lin...

Page 5: ...rel Disassembly mandrel for tapping out the flywheel without damage to the crankshaft thread 944 500 880 4 Setting gauge Gauge for measuring the gap between flywheel and armature 944 500 891 5 Torque...

Page 6: ...essure gauge for checking the carburetor fuel valve 956 004 000 10 Tachometer Electronic tachometer for measuring the engine speed of 2 and 4 stroke engines 950 233 220 11 3 8 socket Installation remo...

Page 7: ...7 15 16 00 SPECIAL TOOLS 15 Sealing plate For sealing intake side 944 603 170 16 Sealing plate For sealing exhaust side 944 603 170...

Page 8: ...he marked portion of the chip deflector 1 Before converting to a 325 chain it will be necessary to install a new chip deflector 957 213 220 CAUTION Before removing the cover plate first set off the ch...

Page 9: ...he condition of the chain sprocket A worn chain sprocket will damage a new saw chain and must be replaced Check the clutch drum needle bearing for wear and damage Assemble the bearing with multi purpo...

Page 10: ...E GUIDE BAR BOLT Removing the brake band CAUTION To prevent cuts wear protective gloves and remove the spike bar 2 bolts Remove the sprocket guard bar and chain Pull the handguard towards the front ha...

Page 11: ...5 0 5 mm and secure with Loctite 243 980 009 000 7 03 CHAIN BRAKE GUIDE BAR BOLT Remove the circlip 7 Pull the handguard and disengagement mechanism up and out parallel to their axes When reassembling...

Page 12: ...socket wrench 8 to turn in the direction of the arrow left hand thread to loosen and remove the clutch Turn the clutch over and remove the disc The flyweights can now be pushed off the guide axially...

Page 13: ...eights Hook the springs as shown in the illustration The press the flyweights onto the guide To do this first push on two flyweights half way then put on the third flyweight by setting it on its edge...

Page 14: ...mm mandrel to knock the valve 10 into the tank and press the new valve in from the outside with an 8 mm mandrel IMPORTANT Use a mandrel with a flat face 1 2 6 4 3 5 7 9 8 10 1 2 3 4 A 05 OIL PUMP Gen...

Page 15: ...new starter cable dia 3 5 mm 1 8 length 980 mm 38 5 as shown in the illustration tie a knot as shown in the illustration in both ends and tighten both knots Put on the cable drum 7 and turn it slightl...

Page 16: ...st If necessary replace spark plug Eliminate cause wrong carburetor setting too much oil in fuel frequent short operations Replace spark plug and check ignition module for corrosion if necessary repla...

Page 17: ...in one hand or place on a soft surface and knock the flywheel loose with a tap on the mandrel Removing the ignition armature Unscrew 2 screws on ignition armature 1 Unscrew ignition cable screw 2 Rem...

Page 18: ...all the way Lay the high voltage cable with the ingition cable as show Fasten the ignition cable with screws 2 Insert the setting gauge 944 500 891 between the ignition armature and the fylwheel Posi...

Page 19: ...nscrew screw 14 Assembly is in reverse order When putting on the carburetor bottom guide the Bowden cable through the opening 17 When installing the fuel hose 18 guide the collar through then opening...

Page 20: ...positioning The seal ring must be centred on the cover of the control side and glued on the whole surface Check control parts control lever inlet needle Check the tip of the inlet needle for wear Chec...

Page 21: ...litate removal of the spring unscrew the screw of spring 3 Remove fan housing Unscrew screw Loosen spring with offset screwdriver 940 827 000 and remove Spring 3 Remove hood Unscrew screw Loosen sprin...

Page 22: ...is then attached to the Bowden clip Guide the pivot axle 7 under the hook on the Bowden clip 6 Before installing the throttle engage the spring in the throttle When installing the throttle lock engag...

Page 23: ...humb off the air valve the negative pressure must quickly return to normal Parts To remove the suction head 10 pull it through the tank opening with a hooked wire Note Do not use pliers as this may da...

Page 24: ...be necessary to remove the carburetor see under 08 CARBURETOR page 19 left and middle of page Connect the over underpressure pump to the connection on the sealing plate 3 Move the piston to top dead c...

Page 25: ...cribed above Connect the over underpressure pump to the connection on the sealing plate 3 Move the piston to top dead centre Set up a negative pressure of max 0 3 bar 4 35 psi If the pressure does not...

Page 26: ...g ring 7 with needle nose pliers Assembling the cylinder and piston Use a new gasket Before assembly lightly oil the cylinder race and piston Push the assembly tool 9 under the piston Position the ope...

Page 27: ...f the ball bearing with Loctite 601 and slide it together with the crankshaft in the warm crankcase without any effort Note Degrease both ball bearings before coating the external ring with Loctite 60...

Page 28: ...ront handle not working Cause Short circuit in the affected handle Diagnosis Both handles are heated constantly or intermittently although the heating switch is on OFF Cause Short circuit at or in swi...

Page 29: ...witch is turned off Check the insulation cap 038 146 030 on the middle contact for damage replace if necessary Switch off switch and pull the plug in the middle Check current between the two connectio...

Page 30: ...rox 0 9 Ohm 10 att approx 20 C 68 F If the resistance is not correct the tank 181 114 170 must be replaced Heating film in front handle 3 Measure resistance between the two solder points on the heatin...

Page 31: ...164 928 405 000 913 455 164 908 905 165 908 905 165 905 808 205 923 208 004 913 850 155 908 905 205 920 308 024 908 905 205 908 905 205 913 455 204 908 905 205 908 905 205 913 455 204 913 455 204 913...

Page 32: ...32 Form 995 726 620 620...

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