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STARTER SYSTEM

CS-271T

2-1 Disassembling starter assembly

1. Remove three screws and remove starter as-

sembly (A) from unit.

2. Pull out starter rope about 30cm (12in) and hold

rope reel (B) by hand. Loop excess rope in rope

reel notch (b) as shown.

3. Rotate rope reel (B) counterclockwise to release

tension of rewind spring.

4. Remove screw (C).

5. Remove pawl catcher (D) and power spring (E).

6. Remove rope reel (B) from starter case (F) slow-

ly to prevent rewind spring (G) from unwinding.

7. Remove rewind spring case assembly (H) from

starter case (F).

838

WARNING

DANGER

Wear eye protection and take care when

removing starter drum. Rewind spring may

unwind suddenly and cause personal injury.

Содержание CS-271T

Страница 1: ...Ord No 401 37 CS 271T ...

Страница 2: ...es problems testing remedies and references We recommend you make use of Operator s Manual and Parts Catalogue togeth er 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 illus trations and directions in this manual are based on the latest pr...

Страница 3: ...RMTION 2 2 STARTER SYSTEM 7 3 IGNITION SYSTEM 13 4 FUEL SYSTEM 22 5 CLUTCH SYSTEM 36 6 CHAIN BRAKE SYSTEM 39 7 SAW CHAIN LUBRICATION SYSTEM 43 8 ENGINE 50 9 TOP HANDLE AND CONTROL SYSTEM 60 10 GUIDE BAR MOUNTING SYSTEM 62 11 MAINTENANCE GUIDE 64 INDEX 68 ...

Страница 4: ...leration pump Model Walbro WT 1008 Venturi size Throttle bore mm in 11 11 14 3 0 437 0 563 Ignition Type CDI Capacitor discharge ignition system Digital Magneto Spark plug BPM8Y CANADA BPMR8Y Starter Type Automatic rewind starter Rope diameter x length mm in 3 5x700 0 14x27 6 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Gasoline Minimum 89 octane gasoline Two stroke air cooled engine oi...

Страница 5: ...screw initial setting turns in 7 8 L mixture needle initial setting turns out 2 H mixture needle initial setting turns out 2 7 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 40 Factory set 7 mL min mL min U S fl oz min BTDC Before top dead center With 12 in guide bar and proper...

Страница 6: ... 40 ON OFF switch M3 3 5 0 3 0 5 3 4 Spark plug M14 130 170 13 17 113 150 Fuel Carburetor M5 30 45 3 4 5 25 40 system Intake bellows M4 35 50 3 5 5 30 45 Clutch Clutch hub LM10 230 260 23 26 200 230 Engine Crankcase M5 55 95 5 5 9 5 48 85 Engine mount M5 70 110 7 11 60 95 Dust cover M4 10 20 1 2 9 18 Eye plate M4 10 20 1 2 9 18 Muffler M5 70 100 7 10 60 90 Muffler cover M5 10 20 1 2 9 18 Others Ex...

Страница 7: ... clearance Max 0 1 0 004 F Piston pin outer diameter Min 7 98 0 3142 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 00 0 4724 L Crankshaft runout Max 0 02 0 001 M Sprocket bore Max 12 80 0 5039 N Clutch drum bore Max 55 5 2 19 P Sprocket wear limit Max 0 5 0 02 1 5 Service Limits 5K177 5K083 5K084 5K081 5K082 5K016 5K025 5K174 5K097 5K178 5K17...

Страница 8: ...earing wedge Removing and crankshaft ball bearings 10 89756319830 Metering lever gauge Measuring metering lever height on carburetor 11 X686000000 ThreeBond 1207D Applying crankcase seam 12 89770511520 Bearing tool Replacing needle bearing on con rod small end 13 91024 Pressure tester Testing crankcase leakages 14 89780079931 Spark tester Checking ignition system 15 89780330133 Pressure tester Tes...

Страница 9: ...E overcomes the load from compression pressure in cylinder crankshaft is 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 disengag...

Страница 10: ...Rotate rope reel B counterclockwise to release tension of rewind spring 4 Remove screw C 5 Remove pawl catcher D and power spring E 6 Remove rope reel B from starter case F slow ly to prevent rewind spring G from unwinding 7 Remove rewind spring case assembly H from starter case F 8 3 8 WARNING DANGER Wear eye protection and take care when removing starter drum Rewind spring may unwind suddenly an...

Страница 11: ...reel 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 Set plate E facing smooth side e to starter rope end Make a knot as shown 7 Tighten knot Push plate and knot into recess of starter grip A B C D ...

Страница 12: ... 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 Assemble rope reel F engaging hook f1 with hook a of rewind spring 4 Check for proper engagement of rewind spring and rope reel by turning rope reel F clockwise and counterclockwise A B E D c C F f1 a a F ...

Страница 13: ...it from unwinding and pull out starter grip to take the rope slack 9 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 clockwise following above step 8 10 Pull out starter rope all the way and check that rope reel can be rotated an additional half or more turn clockwise as shown to prevent rewind ...

Страница 14: ...pinching of torsion spring install these parts without setting the end G of torsion spring on starter pawl The bolt is pre coated with sealant on the thread If the sealant is peeled off apply thread locking sealant Loctite 242 Three Bond 1324 or equivalent 4 Using fine wire H or appropriate tool place the end G of torsion spring on pawl B by hooking and passing under pawl as shown Remove fine wire...

Страница 15: ...IGNITION SYSTEM CS 271T 13 A Flywheel E Spark plug cap B Ignition coil F Switch lead C Spark plug G Ground lead D Spark plug cap coil H Ignition switch 3 IGNITION SYSTEM A B C D E G H F F ...

Страница 16: ... 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 test...

Страница 17: ... not 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 3 3 Inspecting spark plug 1 Remove spark plug to inspect for fouling cracked or broken i...

Страница 18: ...r or multi meter to ignition switch terminal B Connect the other probe to another ignition switch terminal D 4 When ignition switch is upward RUN position tester should indicate infinite resistance 5 When ignition switch is in STOP position tes ter should show that the circuit is in conducting state closed circuit 6 If ignition switch is defective replace with a new one B A D B C ...

Страница 19: ... hexagon wrench B etc and remove screw inside 3 Remove four screws C 4 Remove top handle lid D 5 Disconnect terminals e and remove ignition switch E 6 Assemble new ignition switch passing leads through three guides F 7 Connect terminals of ignition switch 8 Pass leads under fuel lines 9 Reassemble all removed parts A B F D E e a C F ...

Страница 20: ...sistance remove spark plug cap and spark plug cap coil and measure resistance between the conduction wire of high tension lead and ignition coil core 5 If the reading at step 3 or 4 is not in the range of 930 to 970 Ω replace with a new ignition coil Go to 3 8 Replacing ignition coil 6 Remove dust cover Disconnect primary lead terminal C from ignition switch terminal D 7 Disconnect the other prima...

Страница 21: ... gap Refer to 3 9 Setting pole shoe air gaps Tighten two bolts B 7 Set grommet D in place and connect spark plug cap to spark plug Reinstall disassembled parts C 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 re moval from high tension lead B 3 Pull spark plug cap away from high tension lead 4 Inspect spark plug cap...

Страница 22: ...Otherwise piston damage may occur 5 Remove nut A by rotating counterclockwise A A B C 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 be tween flywheel and ignition coil shoes 2 Rotate flywheel until magnetic poles of flywheel face ignition coil shoes 3 Hold ignition coil against flywheel and tighten the bolts to specified torque...

Страница 23: ... to re move flywheel 8 Inspect woodruff key for damage or shearing Replace as required 9 Wipe off oil from taper part of crankshaft and fly wheel before assembling flywheel 10 Install woodruff key 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 clockwise C ...

Страница 24: ...g C Connector D Fuel tank vent E Fuel tank F Fuel strainer G Fuel lines H Carburetor J Air cleaner case K Prevent plate L Air filter M Air cleaner cover N Purge line O Fuel return line P Purge bulb Q Intake bellows R Collar L D E O A B F C N M G H J P K Q R ...

Страница 25: ...n occur from flying particles 3 If heavily blocked with dirt or dust or if heavily soiled or damaged replace air filter with new one 4 2 Inspecting fuel cap and fuel strainer 1 Remove fuel cap 2 Inspect fuel cap for cracks and O ring 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 s...

Страница 26: ...gnose 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 of fuel tan...

Страница 27: ... connect pressure tester 91024 B 2 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 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 as sembly Damage to valves will occur 4 Apply negative pressure 20 kPa 0 2 kgf cm2 3 psi 5 Tank vent...

Страница 28: ...ntly 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 36301100210 E 7x11x170mm and 38201101110 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 a with...

Страница 29: ...cap and remove fuel strainer C and clip D from fuel line E 5 Remove grommet F from the unit together with fuel line and fuel return line 6 Install fuel return line B through grommet F as shown in Fig 1 Place 5 mm 0 20 in dia clip H over fuel line A then install A to pipe joint G and secure with clip as shown Place 6 mm 0 24 in dia clip J over fuel line E then install E to pipe joint G and secure w...

Страница 30: ... for 100 seconds alter nating engine speed between WOT and idle every 5 seconds Adjust idle adjust screw to 3 200 200 rpm Adjust H mixture needle to 11 900 600 rpm by turning H limiter cap If engine does not run cor rectly 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 m...

Страница 31: ...er cap removal tool by turning CW then screw limiter cap removal tool into center hole of previous limiter cap to remove completely 5 Turn L and H mixture needle CW until lightly seated then turn both mixture needles CCW for initial setting as follows L mixture needle 2 H mixture needle 2 7 8 NOTE If needles are forced during seating dam age to carburetor may occur 6 Remove air cleaner cover and a...

Страница 32: ...peed should be less than or equal to 11 400 rpm If rpm is higher turn H mixture needle CCW until 11 400 rpm is achieved To make the final WOT engine speed adjust ment turn the H mixture needle CW in 1 8 turn increments with the engine at idle After each adjustment accelerate to WOT and check rpm The final rpm should fall within 11 600 11 800 rpm 7 After adjusting carburetor screw new limiter cap C...

Страница 33: ... 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 figure at step 5 remove carburetor from the unit disconnecting purge 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 air bubbles come out betwee...

Страница 34: ...red 1 6 5 0 4 1 35 1 5 B A A C 4 10 Inspecting metering lever height 1 Remove carburetor 2 Remove metering diaphragm cover metering diaphragm and gasket 3 Inspect metering lever A height by Metering lever gauge 89756319830 B Metering lever height 1 65 mm 0 065 in lower than diaphragm seat C 4 If necessary gently bend metering lever up or down to set metering lever to proper position NOTE When mete...

Страница 35: ...ows 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 spring metering lever and pivot pin NOTE Insure proper metering lever installation as follows 1 Spring is seated in its hole at chamber floor 2 Spring is un...

Страница 36: ...lve and inlet needle valve spring may be damaged by the compressed air NOTE CS 271T uses an alcohol resistant meter ing diaphragm A The alcohol resistant metering diaphragm has both a square tab a1 and sharper corner a2 as ID mark 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 carburetor as fol...

Страница 37: ...mating surface between carburetor and intake bel lows Use of sealant is no longer required on any CS 271T after confirmation test Effective date March 1 2012 Starting serial number CS 271T 11 11004001 and after CS 271T 12 12008705 and after CS 271T 13 13001901 and after 3 Pass purge line D between throttle rod C and choke knob E 4 Connect purge line D to fitting F of carbure tor A B C D E F C ...

Страница 38: ...UTCH SYSTEM CS 271T 36 5 CLUTCH SYSTEM A Clutch assembly B Clutch plate C Clutch drum D Needle bearing E Collar F Worm gear G Circular washer H Clutch hub J Clutch shoe K Clutch spring J K E D C B A G F H ...

Страница 39: ...ton damage 4 Rotate clutch assembly F clockwise by hand until it cannot be rotated further 5 Loosen clutch assembly Left hand thread ro tating clockwise with clutch tool X640000011 G and remove it NOTE Do not use power tools Otherwise piston damage may occur 6 Remove clutch drum clutch plate needle bear ing collar worm gear and circular washer 7 Inspect clutch shoes for wear and spring for weaknes...

Страница 40: ...bly is installed untie tempo rary 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 by hand until it can not be turned further 4 Tighten clutch assembly Left hand thread with clutch tool X640000011 5 Remove rope from spark plug hole and reinstall all removed parts 5 2 Replacing clutch parts 1 Install clutch spr...

Страница 41: ...STEM CS 271T 39 6 CHAIN BRAKE SYSTEM A Brake lever B Collar C Spacer D Sprocket guard E Compression spring F Spacer G Brake band H Pin J Brake cover K Torsion spring L Brake connector M Spacer G E F D C A H K J B L M ...

Страница 42: ...it 2 Move brake lever A to chain brake engaging position 3 Remove bolt a and remove brake lever A from sprocket guard NOTE Make sure that brake connector B is in engaging position before removing brake cover C otherwise compression spring may jump out Released position Engaging position 4 Loosen two screws D securing brake cover C and remove brake cover 5 Inspect all the brake parts for damage Rep...

Страница 43: ...h d of spacer D as shown Make sure the pin c1 of brake connector C is engaging with the groove F of sprocket guard 3 Slide in compression spring G to the end c2 of brake connector as sown 4 Push compression spring G with driver etc and install compression spring in sprocket guard as shown in the below picture 5 Apply molybdenum grease on entire compres sion spring and other friction parts 6 Reinst...

Страница 44: ...own 2 Set brake lever C on sprocket guard installing torsion spring longer end a2 inside brake lever by bending with driver etc 3 Install collar D on brake lever setting flat sides d as shown 4 Install nut E in collar D facing flat side e to collar D 5 Set spacer F on bolt G and assemble brake cover on sprocket guard A d E C D B e G F a1 a2 a2 d ...

Страница 45: ... 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 7 SAW CHAIN LUBRICATION SYSTEM A Oil cap B O ring C Connector D O ring E Oil tank vent F Engine cover f Oil tank G Oil strainer H Grommet J Oil line K Auto oiler assembly L Oil outlet line M Pipe joint A B F C D E G H K J L A B C D B M ...

Страница 46: ...chain oil in the tank is con sumed 1 Remove starter assembly 2 Remove O ring A 3 Remove oil tank vent B using paper clip and clean it 4 Check that oil tank vent lips b are not hard or deformed Replace as required 5 Install oil tank vent B using suitable tool C as shown 6 Reinstall O ring A as shown Reinstall starter assembly B C A b B A ...

Страница 47: ...t pressure tester 89780330133 E to oil line D NOTE To connect pressure tester to oil line it is recommended to use pipe joint V186000020 F 5 Tighten oil cap and apply pressure approx 9 8 kPa 0 1kgf cm2 1 4psi 6 Pressure should not drop If the pressure drops leakage may occur at oil cap oil cap O ring oil line grommet oil tank vent or oil tank Inspect them and replace defective part s with new part...

Страница 48: ...nk Refer to 7 1 Inspecting oil cap and strainer 5 Pull out oil line A from the unit together with oil strainer D 6 Remove grommet E with longnose pliers etc 7 Insert new oil line F to new grommet G 8 Connect oil strainer D to oil line 9 Pass oil strainer D through grommet hole H and assemble grommet G to grommet hole 10 Make sure oil strainer can move freely in oil tank NOTE If oil strainer cannot...

Страница 49: ...puller 89760323030 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 spring if ...

Страница 50: ...ugh 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 rotat ing plunger NOTE Parts number V ring 43702032430 Plunger 437024...

Страница 51: ...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 oil er body 5 Press adjuster needle H to the bottom orient ing 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 plug ...

Страница 52: ...nder Upper crankcase B Crankcase Lower crankcase C Crankshaft assembly D Ball bearing E Oil seal F Piston ring G Snap ring H Piston J Piston pin K Piston pin spacer L Intake bellows M Engine cover N Dust cover F D B N G A C H K J L M E ...

Страница 53: ... port piston crown and muffler for carbon deposits NOTE Compression pressure varies with volume of compression gauge tip occupying cylinder 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 8 2 Cleaning cooling air passages 1 Remove starter assembly...

Страница 54: ...er Do not use metal tool and be careful not to scratch piston or cylin der NOTE Replace muffler gasket with new one when removing muffler 4 Remove three screws and remove muffler lid D from muffler with muffler lid gasket E Remove spark arrestor screen F 5 Remove carbon deposits from spark arrestor screen F and muffler lid D If screen has heavy deposits replace with new one 6 Reassemble spark arre...

Страница 55: ... and install pressure connec tor A131000150 F to spark plug hole 8 Connect pressure tester 91024 G to pressure connector F 9 Apply pressure approx 19 6 kPa 0 2 kgf cm2 3 psi by pressure tester and leave for 60 seconds NOTE Do not exceed 30 kPa 0 3 kgf cm2 4 3 psi Otherwise damage to oil seal may occur 10 If the reading drops leakage may occur 11 Leakage may occur from crankcase seam or oil seal Us...

Страница 56: ...flywheel Refer to 3 10 Inspecting fly wheel and key 4 Remove ignition coil Refer to 3 8 Replacing ignition coil 5 Remove muffler and heat shield with muffler gasket Refer to 8 3 Inspecting muffler and ex haust port 6 Remove front handle and top handle 7 Remove dust cover and remove two bolts A 8 Remove intake bellows B 9 Remove two bolts C from bottom of the unit 10 Pull out engine block from engi...

Страница 57: ...ton 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 Clean with fine sand pa per oil stone or soft cleaning brush A if carbon is found 3 Inspect top land ring groove and skirt Clean them with soft cleaning brush A if carbon is found NOTE Do not use square end of broken piston ring when cleaning piston ring groove othe...

Страница 58: ...ugh damaged or discolored Replace crank shaft assembly if plastic parts A are damaged 8 9 Replacing oil seal and ball bearing 1 Check oil seal s and replace if defective 2 Check ball bearing s for smooth rotation If not remove ball bearing s using bearing wedge A 89770102830 3 Install new ball bearing s onto crankshaft using bearing seal tool 89772621430 B Bearing should be completely seated again...

Страница 59: ...B in hole a of the base 2 Push needle bearing out from small end using the smaller pusher C 3 Put small end of connecting rod on the base aligning both holes of small end and the base 4 Put a new needle bearing on small end NOTE The side stamped with identification of nee dle bearing should face up 5 Push needle bearing into the bottom using the larger pusher D 1K235 1K236 D B A C a 20mm 0 8in 8mm...

Страница 60: ...mped 8 through piston with piston pin spacers set at step 1 3 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 89770230131 with pusher adapter stamped 8 4 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 5...

Страница 61: ... NOTE When installing piston in cylinder do not twist cylinder to avoid breakage of piston ring and scoring cylinder bore 4 Make sure that rims of oil seal are properly seat ed in the grooves of cylinder upper crankcase 5 Apply liquid gasket ThreeBond 1207D Parts No X686000000 or equivalent on seams C of lower crankcase 6 Apply adhesive Loctite 675 or equivalent on bearing bores D of lower crankca...

Страница 62: ...AND CONTROL SYSTEM CS 271T 60 9 TOP HANDLE AND CONTROL SYSTEM A Front handle B Top handle C Torsion spring D Throttle trigger E Throttle rod F Throttle lockout G Top handle lid H Cushion J Spring D E A B F C G H J ...

Страница 63: ...Assemble throttle rod in the hole a of throttle trigger 7 Assemble top handle cover 9 2 Replacing cushions 1 Remove sprocket guard 2 Inspect cushion A for cracking wear or sepa ration from metal part replace as required NOTE When replacing cushion remove cushion cap B using needlenose pliers as shown NOTE When installing cushion apply lithi um based grease in cushion 3 Remove two screws securing l...

Страница 64: ...tensioner B collar C and bevel gear D Remove bevel gear E 3 Inspect them for damage or wear Replace as required 4 Install bevel gear E into sprocket guard 5 Screw chain tensioner B on tensioner screw A 6 Set bevel gear D in collar C Insert the end a of tensioner screw A in the hole d of bevel gear D 7 Install sub assembled tensioner screw in slot F of sprocket guard confirming engagement of bevel ...

Страница 65: ... If it is hard to remove or broken stud is too short for tightening two nuts hold defective stud by vise and turn the chain saw body counterclock wise or use a suitable stud remover 3 Install two nuts on new stud and tighten them against each other NOTE Apply a small amount of thread locking sealant in the thread hole locktite 675 or equiva lent 4 Turn nut B clockwise to install stud A B ...

Страница 66: ...essive 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 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Flywheel k...

Страница 67: ... 1 8 2 8 3 1 2 8 1 8 4 8 4 8 6 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 9 1 Fuel octane freshness purity 4 7 1 Others Chain brake Cushions Saw chain 6 1 to 6 3 9 2 Replace Sharpen 15 14 13 12 11 10 09 08 07 06 0...

Страница 68: ...tch side oil seal 7 9 Starter side ball bearing 7 9 Starter side oil seal Air filter case 4 1 Carburetor 4 14 Top handle Clutch drum 5 Front handle 3 8 Ignition switch Top handle lid 9 1 7 8 Crankshaft assembly Spark plug 3 3 Clutch assembly 5 Sprocket guard 8 1 10 1 9 1 Compression springs Throttle trigger 9 2 6 6 6 7 Worm gear Flywheel Muffler cover Engine block Engine cover 7 4 Crankcase Cylind...

Страница 69: ... 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 frequency o...

Страница 70: ...switch 13 15 to 18 51 Ignition system 3 6 13 15 Ignition timing 3 Inlet needle valve 31 33 34 Intake bellows 4 22 32 50 54 Key flywheel 20 21 54 L mixture needle 3 28 to 30 Limiter cap 6 28 to 30 Liquid gasket 4 59 Maintenance guide 64 Metering diaphragm 32 34 Metering lever 3 6 31 to 34 Metering lever height 3 6 31 32 Minimum secondary voltage 3 Muffler 2 4 28 51 to 54 59 67 Needle bearing clutch...

Страница 71: ......

Страница 72: ...Printed in Japan 1202 ...

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