Yamabiko ECHO PB-2520 Service Manual Download

Page: 1 / 60

Ref. No. 403-20

(Serial number: 37000001 and after)

PB-2520

ECHO:

shindaiwa:

EB252

Summary of Contents for ECHO PB-2520

Page 2: ...oting 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 speci cations illustra tions and directions in this manual are ...

Page 3: ... 6 2 Inspecting fuel cap and fuel strainer 31 6 3 Inspecting fuel tank and line 32 6 4 Inspecting and replacing tank vent 33 6 5 Replacing fuel line fuel return line tank vent line and grommet 35 6 6 Adjusting carburetor 36 6 6 1 General adjusting rules 36 6 6 2 Initial setting Throttle adjust screw L mixture needle and H mixture needle 37 6 6 3 Adjusting carburetor 37 6 6 4 Inserting limiter plug...

Page 4: ...tem Digital magneto Spark plug NGK BPMR8Y Starter Type Automatic rewind Rope diameter x length mm in 3 0 x 900 0 12 x 35 4 Fuel 1 Type 2 Mixed two stroke fuel Mixture ratio 50 1 2 Gasoline Minimum 89 octane petrol Two stroke air cooled engine oil ISO L EGD ISO CD13738 JASO FC FD Tank capacity Full tank capacity 0 55 18 6 L U S À oz Usable tank capacity 0 50 16 9 Exhaust MufÀer type Spark arrester ...

Page 5: ...t mixture needles Screwdriver 2 5 mm Carburetor adjustment 1 Initial setting H mixture needle turn out 1 3 4 L mixture needle turn out 2 1 2 Throttle adjust screw turn out 1 13 Engine warm up Idle WOT Total sec 10 180 190 2 Find idle maximum speed Adjust L mixture needle to maximum idle speed 3 Set idle maximum speed w TAS RPM 3500 4 Set idle speed by turning L mixture needle CCW RPM 3000 5 Find W...

Page 6: ... 60 95 Engine mount M5 60 80 6 8 50 70 Engine cover M5 35 60 3 5 6 30 50 MufÀer M5 70 110 7 11 60 95 Others Outer fancase M5 35 60 3 5 6 30 50 Fan M6 80 100 8 10 70 87 Regular bolt nut and screw M3 6 10 0 6 1 5 9 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 M8 110 150 11 15 95 130 The torque differences among four bolts should not exceed 20 kgf cm 2N m 17in lbf on one cylin...

Page 7: ...e seen B Piston outer diameter Min 33 91 1 335 C Piston pin bore Max 9 035 0 3557 D Piston ring groove Max 1 6 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 9 038 0 3558 L Crankshaft runout Max 0 02 0 001 ...

Page 8: ...odule air gap gauge Adjusting pole shoe air gaps 10 897712 04630 2 pin wrench Removing and installing pawl carrier 11 A131 000150 Pressure connector Testing crankcase and cylinder leakage 12 897726 21430 Oil seal tool Installing crankcase oil seals 13 897800 79931 Spark tester Checking ignition system 14 897803 30133 Pressure tester Testing carburetor and crankcase leakages 15 91037 Compression ga...

Page 9: ...TEM PB 2520 EB252 7 2 STARTER SYSTEM A E ring B Pawl carrier C Spring D Starter pawl E Screw with washer F Starter rope G Rope reel H Rewind spring J Starter grip K Rope guide L Starter case H F G J C D A K E L B ...

Page 10: ...y hand Loop excess rope in rope reel notch c as shown 3 Rotate rope reel C clockwise to release ten sion of rewind spring 4 Remove screw D with washer 5 Remove rope reel C from starter case E slowly to prevent rewind spring G from unwind ing WARNING DANGER Wear eye protection and take care when removing starter drum Rewind spring may unwind suddenly and cause personal injury C c A B D C G E ...

Page 11: ...ope singe both ends of the rope to prevent fraying 4 Make a knot D at end of starter rope and pass the rope through hole of rope reel then press the knot D into recess as shown 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 Push knot into recess e of starter grip A B C D D E e ...

Page 12: ...than the inner diameter of starter case 3 Retain rewind spring with a pliers as shown Set rewind spring in starter case C hooking the outer hook a3 to the holder c of starter case C 4 Apply small amount lithium based grease to outside of rewind spring NOTE Rewind spring supplied as spare part is shipped in temporary retainer D Retainer should be removed when installing To install new spring wound ...

Page 13: ...s shown Hold rope reel to prevent it from unwinding and pull out starter grip to take the rope slack 5 Pull starter several times to check rewind spring tension If starter is not rewinding fully increase spring tension by rotating rope reel one more turn counterclockwise following above step 4 6 Pull out starter rope all the way and check that rope reel can be rotated an additional half or more tu...

Page 14: ... counterclockwise by hand until it cannot be rotated further 4 Remove starter pawl assembly rotating counter clockwise with 2 pin wrench 897712 04630 D as shown NOTE Do not use power tools Otherwise piston damage may occur 5 Remove E ring E from pawl and replace start er pawl A and spring B 6 Insert spring B to pawl and push pawl into hole near mark R Install E ring E 7 Install starter pawl assemb...

Page 15: ...BLOWER SYSTEM PB 2520 EB252 13 3 BLOWER SYSTEM A Fan case grid B Outer fan case C Fan D Inner fan case A B C D ...

Page 16: ... 4 If clogged with grass or debris remove outer fan case A and clean up inside fan case 5 If defective replace them with new ones Refer to 3 2 Disassembling fan and fan case 3 3 As sembling fan and fan case 3 2 Disassembling and assembling fan and fan case 1 Remove blower pipe 2 Remove seven bolts A that secure outer fan case 3 To remove fan case grid B push the tub b1 on the fan case C as shown N...

Page 17: ... 5 Assemble fan E with two bolts d 6 Assemble outer fan case with seven bolts To assemble fan case grid F push tab f of fan case grid F in place NOTE In the case of replacing the case grid B push tab b2 back and pry up fan case grid b3 as shown to remove fan case grid And install fan case grid B E D F f b2 b3 B ...

Page 18: ...BLOWER SYSTEM PB 2520 EB252 16 3 2 Disassembling and assembling fan and fan case continued To install fan case grid B push tab b2 on grid B with hammer as shown B b2 b2 ...

Page 19: ...IGNITION SYSTEM PB 2520 EB252 17 4 IGNITION SYSTEM A Ignition switch B Ignition switch knob C Spark plug cap coil D Spark plug cap E Spark plug F Ignition module G Flywheel A B C D E G F ...

Page 20: ... OK OK S T Not OK S T Not OK Not OK S T OK S T Not OK Pole shoe air gaps Replace OK OK 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 S T Not OK S T Spark test R T Running test including actual operation OK ...

Page 21: ...test near spark plug hole without spark plug installed otherwise there is a chance to ignite fuel mixture inside cylinder Do not touch metal parts of spark tester while performing the test to avoid receiving electrical shock Do not check spark in area where gasoline is spilled or ﬂammable gases may exist 4 3 Inspecting spark plug 1 Remove spark plug to inspect for fouling cracked or broken insulat...

Page 22: ...nsion lead 4 Inspect spark plug cap coil C for corrosion and correct connection Inspect spark plug cap for cracks Replace as required NOTE Make sure spark plug cap coil C contacts center core of high tension lead when reinstalling it 5 Coat end of high tension lead B with small amount of oil and insert it into spark plug cap A as shown until the spark plug cap coil is properly seated in the cap A ...

Page 23: ...act cylinder n with red probe b2 Secondary coil resistance should be in the range of 960 to 1 000 ȍ 4 If the meter reading indicates in nite resistance remove spark plug cap and spark plug cap coil and measure resistance between the conduction wire of high tension lead and ignition module core 5 If the reading at step 3 or 4 is not in the range of 960 to 1 000 ȍ replace with a new ignition module ...

Page 24: ...eturn line C from carburetor H 3 Remove air lter D two bolts E prevent plate F air cleaner case G carburetor H and intake gasket J 4 Remove starter case reffering to 2 1 Disassem bling starter assembly 5 Remove six bolts K and engine cover L 6 Remove ignition switch M throttle trigger N and throttle rod P A C B A D E F G H K J L P N M K ...

Page 25: ... Remove two bolts W ignition switch terminal n1 remove ignition module V and two washer X from cylinder 12 Remove spark plug cap Y and spark plug cap coil from high tension lead Refer to 4 4 Replacing spark plug cap and coil Install them on new igni tion module V 13 Loosely install new ignition module V ignition switch terminal n1 and two washer with two bolts Set air gap Refer to 4 6 Setting pole...

Page 26: ...s too narrow contact with Àywheel may result When the air gap is too wide spark is weak A B C c1 4 8 Inspecting ignition switch 1 Referring to 4 6 Replacing ignition module re move engine assembly from inner fan case 2 Remove primary lead terminal A from ignition module B 3 Connect one probe of Ohm meter or multi meter to terminal c1 of ignition switch C Connect the other probe to the other termin...

Page 27: ...step 2 When replacing entire ignition switch B go to step 4 2 Remove screw b1 Remove ignition switch knob b2 3 Apply a drop of thread locking sealant Loctite 222 ThreeBond 1342 or equivalent in the screw hole b4 of ignition switch Assemble switch knob b2 and lead terminal b3 with screw b1 4 Install ignition switch B on inner fan case C Install each lead in ribs of inner fan case as shown b1 b2 b3 ...

Page 28: ...ey A B 4 11 Replacing ﬂywheel and key 1 Referring to 4 5 Replacing ignition module re move engine assembly from inner fan case 2 Remove spark plug cap and clean dirt around spark plug Remove spark plug 3 Insert clean rope A in spark plug hole ad equately to stop crankshaft rotation NOTE Do not insert rope end to avoid bite by pis ton and cylinder NOTE Do not use piston stopper to avoid piston dama...

Page 29: ...deformed 8 Wipe off oil from taper part of crankshaft and Ày wheel before assembling Àywheel 9 Install woodruff key into key groove as shown in the picture NOTE If key groove is too tight le woodruff key before installation 10 Align Àywheel cast groove with woodruff key on crankshaft 11 Insert flywheel D and tighten nut B to speci ed torque Refer to Service information 1 3 Torque limits NOTE Be su...

Page 30: ...HANDLE AND CONTROL SYSTEM PB 2520 EB252 28 5 HANDLE AND CONTROL SYSTEM A Inner fan case B Throttle lever C Throttle trigger D Throttle rod E Engine cover F Carburetor D A B F C E ...

Page 31: ...two wash ers throttle lever E and nut from inner fan case A 5 Inspect throttle rod B throttle trigger C and throttle lever E for wear damage or deformation Replace as required 6 Set nut F on inner fan case A 7 Assemble washer G throttle lever E washer H and spring washer J with bolt D on inner fan case A 8 Set throttle trigger B on boss a1 of inner fan case A as shown 9 Apply lithium grease with b...

Page 32: ...er C Prevent plate D Air cleaner case E Carburetor F Intake gasket G Intake insulator H Intake gasket J Fuel cap K Gasket L Connector M Fuel tank N Fuel line P Fuel return line Q Fuel strainer R Fuel tank vent S Tank vent line T Grommet U Pipe joint B C D E F G H J K L N P M N Q R S T U ...

Page 33: ...ressed air Eye damage can occur from ﬂying particles 3 If heavily blocked with dirt or dust or if heavily soiled or damaged replace air lter with new one 6 2 Inspecting fuel cap and fuel strainer 1 Remove fuel cap 2 Inspect fuel cap for cracks and gasket A for cuts or damage and replace with new one as re quired 3 Pull fuel strainer B out from fuel tank using a wire hook C Clean fuel strainer Repl...

Page 34: ...nds of longnose pliers with tape or cover with soft pipes to protect fuel line from damage 5 Apply pressure approx 50 kPa 0 5 kgf cm2 7 psi 6 If pressure drops replace fuel line 7 Put fuel strainer in fuel tank and fasten fuel cap securely 8 Apply pressure approx 10 kPa 0 1 kgf cm2 1 4 psi 9 Pressure should not drop If pressure drops leakage may occur from fuel cap fuel cap O ring mating surface o...

Page 35: ...tester 91139 C to tank vent B 3 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 4 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 5 Apply negative pressure 5 8 inHg 20 kPa 0 2 kgf cm2 3 psi 6 Tan...

Page 36: ...ge 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 hole...

Page 37: ... B and tank vent line C to grommet E Adjust each length as follows NOTE Pay attention to the position of grommet projection e1 NOTE Make sure fuel line a1 has ID mark EPA KEP 001 lot xxxx on it 7 Place clip F over fuel line G then install fuel line G to pipe joint H and secure with clip F Connect pipe joint H with fuel line G to fuel line A 8 Connect fuel strainer to fuel line G Connect tank vent ...

Page 38: ...just throttle adjust screw to 2 800 3 200 RPM Make sure WOT engine speed is over 7 150 RPM again If engine does not run correctly after this adjustment proceed to the next step 6 6 2 2 A D B C 1 2 3 6 6 2 Initial setting Throttle adjust screw L mixture needle and H mixture needle Tools Required P N G310 000050 Tachometer PET 304 P N Y089 000094 Carburetor adjustment tool KIT Driver 2 5mm P N 91077...

Page 39: ...0 seconds at WOT 2 Adjust L mixture needle A using 2 5 mm blade screwdriver E to reach maximum engine speed just before lean drop off 3 Set idle speed to 3 500 RPM by turning Throttle adjust screw D Engine RPM should be stable at 3 500 RPM after Throttle adjust screw adjustment 4 Turn L mixture needle A CCW to reduce idle speed 500 RPM to set idle speed at 3 000 RPM The idle speed range is 2 800 t...

Page 40: ...T and idle speed in eld oper ation may vary from nal adjustment speci cations due to changing ambient conditions fuel and en gine loads Safe engine RPM variances should be within the safe ranges for WOT and Idling speed as listed in Section 1 2 otherwise the carburetor should be readjusted IMPORTANT The limiter plugs must be properly installed in L and H mixture needle holes to com ply with Emissi...

Page 41: ...m2 7 psi 6 If reading does not drop inspect inlet needle valve for sticking or metering lever height is too low 7 If pressure drops at step 3 or if pressure drops below standard gure at step 5 remove carbure tor from the unit disconnecting fuel return line and throttle rod 8 Submerge carburetor in suitable clean solvent to locate the leak by applying pressure approx 100 kPa 1 kgf cm2 14 psi 9 If a...

Page 42: ...r replace as required 6 9 Inspecting metering lever height 1 Remove carburetor 2 Remove metering diaphragm cover metering diaphragm and gasket 3 Inspect metering lever A height by slide gauge B Metering lever height 0 1 0 25 mm 0 004 0 010 in lower than diaphragm seat D 4 If necessary gently bend metering lever up or down to set metering lever to proper position NOTE When metering lever is Too hig...

Page 43: ...edle valve spring metering lever and pivot pin NOTE Insure proper metering lever installation as follows 1 Spring is seated in its hole at chamber Àoor 2 Spring is under dimple of metering lever 3 metering lever fork is holding inlet needle valve 6 11 Inspecting diaphragm 1 Check metering diaphragm A for hardening distortion or pin hole Replace it as required 2 Remove pump body assembly B and pump...

Page 44: ...insulator and carburetor B 2 Connect fuel line C to fuel inlet of carburetor B Connect fuel return line D to fuel outlet of carburetor B 3 Connect throttle rod E to carburetor B 4 Assemble prevent plate F air cleaner case G carburetor B and intake gasket A to intake insu lator A B C D E F G B A ...

Page 45: ...Cylinder B Cylinder gasket C Piston ring D Piston E Snap ring F Needle bearing G Piston pin spacer H Crankcase J Oil seal K Dowel pin L Ball bearing M Crankshaft assembly N Piston pin P Crankcase gasket A B C D E F G H H J J K L L M N P ...

Page 46: ...combus tion 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 passages NOTE To maintain proper engine operating tem peratures cooling air must pass freely through the cylinder n area This Àow of air carries combus tion heat away from th...

Page 47: ...d 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 mufÀer gasket with new one when removing mufÀer 3 Remove bolt B and spark arrestor screen C from mufÀer 4 Remove carbon deposits from spark arrestor screen C If screen has heavy deposits replace with new one 5 Reassemble spark arrestor screen C and tight en bol...

Page 48: ...essure connec tor A131 000150 E to spark plug hole 5 Connect pressure tester 91139 F to pressure connector E 6 Apply pressure approx 50 kPa 0 5 kgf cm2 7 3 psi by pressure tester and leave for 30 seconds 7 If the reading drops leakage may occur 8 Leakage may occur from crankcase seam or oil seal Use soapy water to locate leakage 9 Then apply negative pressure approx 30 kPa 0 3 kgf cm2 4 4 psi by p...

Page 49: ...ls or damage to cylin der wall may result 3 Inspect cylinder wall and replace with new one if plating is worn peeled away scored or exposing cylinder base metal 7 5 Replacing oil seal 1 Pry defective oil seal from engine NOTE Be careful not to damage housing of oil seal in crankcase 2 Apply grease on dust lip and seal lip of new oil seal A to avoid damage of lips while inserting crankshaft into oi...

Page 50: ...piston pin out from piston NOTE If piston pin is tight use piston pin tool 897702 30131 F with adapter G stamped 8 on an end and piston holder 897719 02830 H 6 Inspect needle bearing and washers and re place if wear or discoloration is noted G H F 7 8 Disassembling crankcase 1 Remove cylinder gasket and piston 2 Remove woodruf key from crankshaft Àywheel end 3 Remove three crankcase bolts 4 Screw ...

Page 51: ...dapter C inner dia 12 mm outer dia 19 mm as shown 5 Tighten shaft B with wrench to remove ball bearing 6 Coat bearing housing in crankcase with a lithium grease 7 Set ball bearing with boss A shaft B and adapter D inner dia 12 mm outer dia 27 5 mm as shown 8 Tighten shaft B with wrench to press ball bear ing into the crankcase half NOTE Preheat around bearing housing of crank case using a floodlig...

Page 52: ...lves together and check crankshaft for smooth rotation NOTE If crankshaft doesn t rotate smoothly tap both ends of crankshaft with plastic mallet several times And recheck crankshaft for smooth rotation 6 Carefully remove excess portion of crankcase gasket C with sharp knife B A C 7 11 Installing piston 1 Place piston over the small end of connecting rod so that the arrow mark A on piston points t...

Page 53: ...eBond 1324 or equivalent on several spots of the bottom of cylin der gasket C to x it on crankcase temporarily 3 Apply oil to piston ring and cylinder internal wall 4 Install cylinder over piston ensuring that exhaust side of cylinder is at arrow side B of piston NOTE When installing piston it is convenient to use piston holder 897719 02830 E for stabilizing piston NOTE Do not twist cylinder while...

Page 54: ...trol system and switches 4 5 Inspecting ignition module 4 6 Replacing ignition module 4 8 Inspecting ignition switch 4 9 Replacing ignition switch 5 1 Disas sembling and assembling handle and control parts 3 Assembling fuel tank and lines 6 3 Inspecting fuel tank and line 6 5 Replacing fuel line fuel return line tank vent line and grommet 4 Assembling fan and fan case 3 3 Assembling fan and fan ca...

Page 55: ...uel tank Cylinder 7 6 Oil seal starter side 7 5 Crankcase 7 9 7 11 Oil seal fan side 7 5 Piston 7 7 7 12 Piston ring 7 7 7 12 Crankshaft 7 9 7 11 Ball bearings 7 10 Needle bearing 7 8 Starter assembly 2 1 Pawl carrier 2 5 Intake insulator Carburetor Air filter 6 1 Air cleaner cover Spark plug Muffler Fan case cover 3 2 Blower fan 3 2 Engine cover 4 6 6 6 6 12 ...

Page 56: ...rheats Engine misfires Engine others are extremely noisy Fuel consumption is excessive Vibration is excessive Engine does not stop INSPECTING Starter system Starter pawl spring Rewind spring Ignition system Sparks Spark plug Spark plug cap coil Ignition switch Ignition coil Pole shoe air gaps Flywheel 2 5 2 3 4 2 4 3 4 4 4 8 4 5 4 7 4 10 Inspecting first 13 12 11 10 09 08 07 06 05 04 03 02 01 13 1...

Page 57: ...st port 7 3 Cylinder compression 1 2 7 1 INSPECTING 13 12 11 10 09 08 07 06 05 04 03 02 01 Engine 13 12 11 10 09 08 07 06 05 04 03 02 01 REFERENCES Crankcase pulse passage 6 8 Carburetor diaphragm 6 11 Carburetor Welch plug 6 12 Fuel 1 1 Oil 1 1 Throttle lever 5 1 Cylinder 7 6 Crankcase cylinder sealings 7 4 Piston Piston ring 7 7 Blower 13 12 11 10 09 08 07 06 05 04 03 02 01 Fan 3 1 3 2 Fan case ...

Page 58: ...tank Clean inside 6 3 6 4 Spark plug Clean Regap 4 3 Inspect Replace 4 2 4 3 MufÀer Spark Arrestor Inspect Clean Replace 7 3 MufÀer and exhaust port Inspect Clean 7 3 Throttle connecting rod Grease 5 1 Leads and connections Inspect Repair 4 8 4 9 Starter system Inspect Repair 2 1 to 2 5 Daily Inspecting in every services IMPORTANT Service intervals shown above are maximum Actual use and your exper...

Page 59: ......

Page 60: ...Published by YAMABIKO Corp Tokyo Japan 1804 ...

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