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55

5

505 38 17-05

Cylinder and piston

Assembly

All models

Fit the piston on the connecting rod.

Make sure that the arrow on the piston top
is turned to the exhaust port.

Assembly

All models

Before fitting the piston and cylinder see
the section ”Cleaning, inspection” and
”Analysis and procedures”.

Lubricate the piston bolt’s needle bearing
with a few drops of engine oil.

Align the arrow on the piston top with the
exhaust port.

Press in the piston bolt by means of the
mandrel 505 38 17-05 and fit the circlips
by means of a pair of flat pliers. Check
that they sit correctly in their grooves by
turning them with the pliers.

Procedure:

In severe cases - replace the cylinder.
Repair the thread with Heli-Coil.

Rub the damaged part with fine emery cloth to remove
adhered aluminium.

With deeper seizure scratches the cylinder and piston should
be replaced.

Replace cylinder and piston.

Rub the damaged part carefully with a fine file or emery cloth.
Before the piston is fitted the cylinder should be rubbed as
above. With deeper scratches the piston and where necessary
also the cylinder should be replaced.

Carefully loosen the piston ring and clean the groove very
carefully before assembly. Check the wear on the piston ring
by placing it in the lower part of the cylinder.

Service tips

Defect:

Broken cooling fins, damaged threads or broken screw at
exhaust port.

Seizure marks in the cylinder bore (especially at the exhaust
port).

The surface lining in the cylinder bore is worn (primarily at
the head of the cylinder).

The piston displays seizure scratches.

The piston ring is stucked in its groove.

Wear tolerances

Cylinder bore

Piston ring gap

The surface finish is worn away
revealing the aluminium.

Max. 1.0 mm (0.04") with the piston
ring pushed into the lower part of
the cylinder.

Max. 0.15 mm (0.006"). Clean the
groove carefully before checking
the mea-surement.

Max. 1.6 mm (0.06"). Clean the
groove carefully before checking the
mea-surement.

Piston ring groove

Piston ring play

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Содержание K 650/700 Active

Страница 1: ...PARTNER R Workshop Manual ...

Страница 2: ... Contents General recommendations 2 1 Starter unit 3 2 Ignition system 11 3 Fuel system 19 4 Centrifugal clutch 41 5 Cylinder and piston 47 6 Crankshaft and crankcase 59 7 Cutting equipment 77 8 Tools 85 9 Technical data 93 This manual covers models K 650 700 Active K 950 1250 Active ...

Страница 3: ...carefully when using cleaning liquids Make sure that there is adequate ventilation when handling petrol and other viscous liquids Theengineexhaustfumesaretoxic Testruntheengineoutdoors Special tools Some work procedures in this Workshop Manual require the use of special tools In each section where this is appropriate the tool and order number are illustrated We recommend the use of special tools p...

Страница 4: ...3 1 Starter unit 1 Contents Dismantling of the starter unit 4 Replacing the starter cord without dismantling the pulley 5 Dismantling 7 Assembly 8 ...

Страница 5: ...ntling of the starter unit Mod 650 700 Untighten the screws for the air filter cover Lift off the cover and intermediate wall Release the screw A and lift off the cylinder cover Dismantle the starter unit from the engine body Untighten all the screws and lift off the starter unit Release the spring tension Pull out the starter rope approx 30 cm 12 in Hold the pulley with your thumb and place the c...

Страница 6: ...ng the pulley Mod 650 700 950 1250 Remove any remaining rope from the pulley and check that the return spring recoils Insert the new starter rope through the hole in the pulley Replacing the starter cord without dismant ling the pulley Mod 650 700 950 1250 Remove any remaining rope from the pulley Check that the return spring and its attachment in the pulley has not been damaged by turning the pul...

Страница 7: ... the starter cord up into the cut out in the pulley Wind the pulley 7 turns clockwise Pull the cord out completely and check that the pulley can be turned at least a further half turn 4 Pullthecordoutcompletelyandcheck that the pulley can be turned at least a further half turn 3 Wind the pulley 7 turns clockwise Be careful and brake the pulley with your thumb Tension the return spring 1 Checkthats...

Страница 8: ...ette is pre tensioned and can if not handled carefully during dismant ling fitting fly out and cause perso nal injury Mod 1250 Remove the screw in the centre of the pulley and lift off the pulley Make sure that the return spring is completely released and dismantle the pulley Mod 1250 Remove the screw in the centre of the pulley and lift off the pulley Make sure that the return spring is completel...

Страница 9: ... the cord in the pulley Push the pulley on the shaft stem Anchor the cord round the pulley hub as shown in the illustration Push the cord down on the shaft journal in the starter unit housing Make sure that the return spring grips in the pulley Lubricate the starter housing stem and pulley with a few drops of oil Assembly Mod 650 700 950 Clean the starter unit components and fit the spring cassett...

Страница 10: ...n in the starter unit cover Lubricate the spring with a few drops of oil Anchor the cord in the pulley Push the pulley down onto the shaft jour nal Tension the return spring Checkthatthespringtensioniscompletely released and lift the starter cord up into the cut out in the pulley Wind the pulley 7 turns clockwise Pull the cord out completely and check that the pulley can be turned at least a furth...

Страница 11: ...ter cord a little Place the starter unit in position Release the star ter cord and check that the pawls engage the pulley Tighten the screws Enter the cord through the cord guide in the starter unit and anchor it in the starter handle with a double knot Anchor the starter cord in the starter handle with a double knot ...

Страница 12: ...11 2 Ignition system 2 Contents The principle of the ignition system 12 Checking the ignition spark 13 Replacing the spark plug protection 15 Dismantling 15 Starter pawls 17 Assembly 17 ...

Страница 13: ...nt of the ignition point is possible or necessary The ignition module is built up of an iron core C Round this lies the primary coil A which consists of a small number of turns of thick copper wire Outside this lies the secondary coil B which has a very large number of turns of copper wire The trigger unit F is fitted on the secondary coil and has the purpose of breaking the current D in the prima...

Страница 14: ...s a spark by pulling the engine over with the starter Try with test plug No 502 71 13 01 if there is no spark Check if there is a spark by pulling the engine over with the starter Groundtheplugtothecylinderandbriskly pull the starter handle Make sure that the stop switch is in the start position There should be a spark between the electrodes If there is no spark try with test plug No 502 71 13 01 ...

Страница 15: ...before fitting Grease the cable ends to simplify fitting and to prevent moisture penetrating into the connections Check the other cables and connections Still no spark Check the other cables and connections for poor contact dirt corrosion cable break and damaged insulation Tips Use an Ohm meter to check if there is a cable break e g as a result of pinching Check the air gap Still no spark Check th...

Страница 16: ... 5 mm 3 16 to obtain full contact with the spark plug protection 3 Fit the contact spiral on the ignition cable and make sure that the wire is folded along the cable 4 Pull the contact spiral in the plug protection NOTE It is important that the point on the contact spiral meets the middle of the ignition cable to prevent sparking Dismantling Mod 650 700 Dismantle the cylinder cover plug star ter u...

Страница 17: ...st rest against the front of the cylinder wall when the piston approaches Top Dead Centre Mod 650 700 950 1250 Dismantle the starter pawls Mod 650 700 950 1250 Dismantle the starter pawls by releasing the screws Make sure the small washer which lies next to the flywheel is not lost Pull off the flywheel Remove the flywheel by means of fly wheel puller 502 51 49 02 which is screwed tight in the hol...

Страница 18: ... 950 1250 Check the starter pawls for wear and damage Replace damaged parts The pawls are mounted on the flywheel with a contact screw Pay attention to the spacer washer A during dismantling and assembly Assembly Check that the keyway and key in the crankshaft are undamaged Mod 650 700 1250 Assembly Check that the keyway and key in the crankshaft are undamaged Mod 650 700 1250 Fit where appropriat...

Страница 19: ...he other parts in the reverse order to dismantling Fit the ignition module Adjust the air gap to the correct size 0 3 0 5 mm 0 012 0 020 See also page 14 15 Fit the other cables and make sure that they are correctly positioned in the cable grooves etc so that they cannot be damaged Fit the other parts in the reverse order to dismantling ...

Страница 20: ...r 22 Carburettor dismantling assembly 23 Carburettor design 25 Jets 25 Speed limiter 26 Compensation device for blocked air filter 26 Disassembly of the carburettor 27 Assembly of the carburettor 30 Carburettor setting 32 Tank air vent 34 Throttle control 35 Trouble shooting 40 3 ...

Страница 21: ...d lift off the air filter cover with the main filter intermediate wall and protective filter Air filter Mod 650 700 950 1250 Release the two screws which hold the air filter cover mod 1250 three screws Lift off the cover with main filter inter mediate wall and protective filter Clean the protective filter by tapping it against your hand The protective filter is made of paper and therefore must not...

Страница 22: ...f the nozzle to the carburettor chamber is tight 3 The nozzle attachments are not broken 4 The fan spiral and air conductor are clean The centrifugal cleaning nozzle is accessible for cleaning or replacement after dismantling the starter unit and air conductor Centrifugal cleaning Active Mod 650 700 Considerably longer cleaning intervals for the air filter are achieved by using the centrifugal for...

Страница 23: ... NOTE Makesurethatthefilter sconnectingcollar is pressed as far as possible in the fuel pipe Mod 950 1250 The fuel filter is located on the hose in the fuel tank It is accessible through the refill hole Remove the tank fuel cap completely Pull out the filter with tool 502 50 03 01 Pull the metal ring A from the filter connection and then pull the filter off the hose to either clean it or replace i...

Страница 24: ...tion and middle piece Forserviceproceduressee Disassembly of carburettor Mod 650 700 Remove the screw guide and lock was her which holds the throttle push rod at the lever Mod 650 700 1 Remove the screw guide from the carburettor s adjusting screws 2 Bend away the lock washer which holds the throttle push rod at the lever by means of a screwdriver NOTE EPA models have fixed jets and conse quently ...

Страница 25: ...m the crankcasesinceitisdifficulttorefitwithout separating the crankcase and tank part Assembly Mod 650 700 Fit the carburettor to the cylinder in the reverse order to dismantling Use new seals Place the air filter connection with screws choke control and middle piece on the carburettor Holdthecompletecarburettorunitagainst thecylinder Pressdownthechokecontrol in its guide and tighten the screws C...

Страница 26: ... to the correct proportions in this part of the carburettor The choke E and throttle valves F are placed here The main jet nozzle is located in the middle of the venturi the narrowest point on the inlet Pumping section This pumps fuel from the tank to the carburettor Pumping section The pump diaphragm G which pumps fuel from the tank to the carburettor s metering unit is located here The membrane ...

Страница 27: ...his transfers the underpressure in the carburettor s inlet to the top of the metering diaphragm as opposed to the atmospheric pressure in a standard carburettor The pressure difference between the top and bottom of the diaphragm therefore remains constant and does not increase as the air filter becomes blocked The fuel supply to the carburettor s main jet nozzle is therefore always maintained at t...

Страница 28: ...a basin with petrol to simplify inspection for leaks Pressure test with 0 5 bar No leakage is permissible Fuel system K650 Active K700 Active Carburettor Induct pipe Seal Insert seal Screwdriverguide HS175E 503 28 03 20 506 21 41 01 506 22 65 01 Black Not compensated Black Rubber foam bonded to cyl housing K650 Active II K700 Active II Carburettor Induct pipe Seal Insert seal Screwdriverguide HS17...

Страница 29: ...r wear in the grooves for the needle valve and the diaphragm Replace damaged parts with new ones If the new needle valve also leaks the fault may be that the seat for the valve is damaged Remove the pump diaphragm Check the diaphragm for damage Remove the fuel strainer Remove the screws which hold the cover over the pump diaphragm Lift off the cover gasket and diaphragm Check the diaphragm for dam...

Страница 30: ...Dismantle the welch plug 1 and main jet nozzle 2 Drill a small hole in the welch plug 1 and carefully remove it with a pointed tool Press out the main jet nozzle 2 with a suitable mandrel Check the valves and valve shafts for wear Replace if necessary On EPAmodels which have fixed nozzles the nozzles can be cleaned or changed once the seal plugs have been removed Carefully drill a small hole Ø 2 m...

Страница 31: ...valves are correctly tur ned and that they seal completely in closed position Use Loctite on the valve screws Tips Number designations on the valves should be able to be read from outside Replace the fuel strainer if it is damaged or cannot be cleaned Fit the pump unit parts in the reverse order to dismantling Place the pump diaphragm closest to the carburettor housing followed by the gasket and c...

Страница 32: ...themeteringdiaphragm NOTE Make sure that the pin on the diaphragm goes into the groove on the lever Fit the blue compensation insert and then the cover Mod 950 The carburettor is of Tillotson HS 282A manufacture and has in principle the same design as the carburettor for mod 650 700 The speed limiter however has been replaced by an electronic limit via the ignition system The adjustable jets have ...

Страница 33: ...n be dismantled for cleaning or replacement Fit the carburettor on the engine in the reverse order to dismantling Use new gaskets Check that the gaskets are turned the right way round so that the impulse channel is not blocked Carburettor setting not EPA models WARNING When test running the engine in connection with the adjustment of the carburettor the clutch cutting arm and cutting disc must alw...

Страница 34: ...adjusted High speed nozzle H not EPA models The engine has a carburettor with built in speed limiter At maximum revs the engine receives an extra volume of fuel which prevents the engine overspeeding The speed limiter has a fixed setting and cannot be adjusted Screw in the H needle to the limiting position where the engine begins to falter during acceleration Use short rapid bursts from idling spe...

Страница 35: ...age If the L and H nozzles are set too rich this will result in acceleration problems or low working speed Mod 950 The fuel tank venting is conducted via a non return valve of the same design as on the other machine models It is accessible when the tank unit and crankcase are separated Remember when servicing to clean the small metal filter A placed in the end of the hose The non return valve B ca...

Страница 36: ...just enough to gain access to the tank vent Throttle control Dismantling assembly Mod 650 700 Remove the four screws which hold the left hand half of the rear grip Note that they have different lengths Throttle control Dismantling assembly Mod 650 700 Remove the four screws which hold the left hand half of the grip Fuel system Prise away the non return valve with a screwdriver Install new componen...

Страница 37: ...ok the spring in the hole in the throttle control 5 Move the throttle control to the correct position opposite the screw hole 6 Press in the start throttle catch and lock the throttle control in start posi tion 7 Insertthescrewinthethrottlecontrol s supporting sleeve Fit in the reverse order to dismantling Replace damaged or worn parts Fit all parts in the left hand half of the grip 1 Place the sp...

Страница 38: ...tion damper 1 Press out the bearing pin 1 with an appropriate punch Ø 2 5 mm far enough so that the safety catch 2 can be removed 2 Press out the bearing pin 3 far enough so that the throttle control can be removed where appropriate by bending it with a screwdriver Fit the safety catch 3 Make sure that the throttle control spring is on the right hand side of the catch seen from behind and that it ...

Страница 39: ...opriate see chapter on vi bration damper Press off the three bearing pins with a suitable punch Ø 2 5 mm Press the safety catches forwards downwards and lift them up at the back edge Press down the safety catch and press it forwards where appropriate with a small screwdriver so that it can be lifted up at the back edge Pull the throttle control forwards and out of the rear grip Pull the throttle c...

Страница 40: ...hole in the throttle control 4 Press down the safety catch until it clicks into the throttle control 5 Press in the three bearing pins and check that the throttle control and safety catch function as intended Fit the throttle control and safety catch in the reverse order to dismantling Check that the spring on the catch goes into the hole in the throttle control Fuel system ...

Страница 41: ...em 3 Plugged tank vent 4 Plugged tank filter 5 Restricted fuel line 6 Dirt in fuel passage 7 Loose damaged fuel line 8 Leak in pulse system 9 Restricted pulse channel 10 Loose pump cover screws 11 Defective pump diaphragm Air system 12 Plugged air filter 13 Defective manifold gasket 14 Loose carburettor mounting screws 15 Worn throttle assembly 16 Incorrect throttle assembly 17 Loose throttle valv...

Страница 42: ...41 Centrifugal clutch 4 Contents Dismantling all models 42 Dismantling mod 650 700 42 Dismantling mod 950 1250 44 Assembly mod 650 700 45 Assembly mod 950 1250 46 ...

Страница 43: ...un at idling speed without the cutting equipment rotating WARNING Never start or test run the engine if the clutch cover is removed The clutch can come loose and cause personal injury Mod 650 700 Fit piston stop No 502 54 15 01 in the spark plug hole Dismantle the clutch clockwise by means of a suitable box spanner Mod 650 700 Fit piston stop No 502 54 15 01 in the sparking plug hole Dismantle the...

Страница 44: ...itable sleeve Ø 17 5 mm 0 69 Clean and inspect the clutch parts for damage and wear Cleanandinspecttheclutchhub sspokes and the clutch shoes for wear There must be material thickness of at least 1 mm 0 04 left at the most worn point on the clutch shoes All the shoes must be replaced at the same time Inspect the wear on the clutch drum the pulley and the inner diameter It must not exceed 75 5 mm 2 ...

Страница 45: ...move the clutch springs with a small screwdriver Remove the clutch springs with a small screwdriver Clean and inspect the clutch parts for damage and wear Clean and inspect the clutch hub spokes and the clutch shoes for wear There must be at least 1 mm of material left at the most worn part of the clutch shoes All the shoes must be replaced at the same time Inspect the clutch drum for wear on the ...

Страница 46: ...tch Place two clutch shoes and the spring on the clutch hub Fit together the centrifugal clutch Place two clutch shoes and the spring on the clutch hub NOTE The spring s coupling point should lie opposite one of the hub s spokes Check that the lubrication hole in the crankshaft is not blocked If necessary clean with a steel wire Fit the remaining clutch shoe Fit the remaining clutch shoe Use plier...

Страница 47: ... lubrication The clutch drum s bearing is lubricated automaticallywiththeoilinthefuelmixture which is pressed out through the channel in the crankshaft Mod 950 1250 Fit the clutch shoes on the hub Fit the springs from the back of the clutch bypressingtheminplacewithyourthumbs or with a screwdriver Check that the lubrication hole in the crankshaft is open Clean it with a piece of wire if necessary ...

Страница 48: ...47 Cylinder and piston 5 Contents Dismantling 48 Cleaning inspection 50 Analysis and procedures 51 Service tips 55 Wear tolerances 55 Assembly 55 Decompression valve 57 Compression test 58 ...

Страница 49: ...tling work is basically the same for all models In the event that the work methodology differs for any particular model this is reported separately Dismantle the following Cylinder cover carburettor cover starter unit plug air filter carburettor inlet manifold muffler with heat shield and on certain models also heat cover ignition module flywheel and Active nozzle See respective sections in the Wo...

Страница 50: ...0 18 01 in the centre of the vibration damper and unscrew the screw which holds the damper to the cylinder Unscrew the cylinder screws with key 502 50 64 01 Lift the cylinder straight up and place a clean cloth in the crankcase opening to prevent dirt from dropping down into the crankcase Dismantle the intake pipe and impulse hose Inspect the parts and replace them if they show signs of cracking U...

Страница 51: ...e piston both the piston and piston bolt should be replaced Check the needle bearing If it is discoloured or damaged it should be replaced Check the circlips If they show signs of cracking or are discoloured they should be replaced Unscrew the cylinder screws and lift off the cylinder Dismantle the spacing piece from the cylinder Unscrew the cylinder screws with key No 502 50 57 01 3 16 and lift t...

Страница 52: ...linder wall which has resulted in an additional powerful increase in heat in the piston Seizure scratches can be seen along the full piston skirt both on the exhaust side and inlet side Medium sized to deep scratches along full piston skirt on exhaust side Reasons Incorrect carburettor setting Recom mended max revs has been ex ceeded Incorrect oil mixture in the fuel Too low octane rating in the f...

Страница 53: ...roove Black discolouring under the piston ring resulting from so called blow through Piston damage resulting from excessively high engine revs Typical damage resulting from excessively high engine revs include fracture of the piston ring broken circlip for the piston bolt defective bearings or the loosening of the guide pin for the piston ring Piston ring fracture A too lean carburettor setting re...

Страница 54: ...aring malfunction Malfunctioning of the crank shaft or connec ting rod bearings is usually the result of excessively high engine revs which result in overloading or overheating of the bearing This in turn can imply that the bearing needles or balls slip instead of rotating whichcanresultinthebearingcagebreaking up The broken parts can become jammed between the piston and the cylinder wall and resu...

Страница 55: ...n deposits on the head of the piston and in the piston ring groove The piston ring is stuck in the groove Piston material is worn off The lower part of the piston skirt on the inlet side is thinner than on the exhaust side Large softer particles which have entered the engine result in damage to the piston skirt under the piston ring as shown in the illustration Reasons The air filter is incorrectl...

Страница 56: ...n Rub the damaged part carefully with a fine file or emery cloth Before the piston is fitted the cylinder should be rubbed as above Withdeeperscratchesthepistonandwherenecessary also the cylinder should be replaced Carefully loosen the piston ring and clean the groove very carefully before assembly Check the wear on the piston ring by placing it in the lower part of the cylinder Service tips Defec...

Страница 57: ... crosswise Mod 650 700 Fit the cylinder in the same way as described above Check the middle piece for cracking or other damage before fitting it Replace the middle piece if necessary Fit the carburettor and other parts in the reverse order to dismantling Mod 650 700 Fit the cylinder in the same way as described above Check the middle piece for cracking or other damage before fitting it Replace if ...

Страница 58: ...ct pressure gauge 502 50 38 01 to the valves thread 2 Pump up the pressure to 80 kPa 0 8 bar 3 Check the pressure after 30 sec It must not be less than 60 kPa 0 6 bar If so rub down the valve disc again Mod 1250 Follow the instructions for Cleaning inspection Assembly and Decom pression valve before fitting the piston cylinder NOTE Fit the spacing piece and throttle wire guide on the cylinder befo...

Страница 59: ...re that it is tight between the cylinder and gauge 3 Move the stop switch to the stop position 4 Firmly pull the engine over 5 6 times 5 Read off the pressure on the gauge Release the pressure by pressing in the valve cone on the side of the gauge connection Repeat this procedure twice and calculate a mean value from the tests NOTE If the engine has been disassembled it should be run in first in o...

Страница 60: ...aft and crankcase Contents Replacing the seal on flywheel side 60 Replacing the seal on clutch side 61 Vibration dampers 62 Dismantling assembly 66 Repair bushing 69 Inspection of crankshaft 71 Pressure test 72 6 ...

Страница 61: ...stion chamber The crankcase must be completely tight in order not to interfere with the pump function Theremustbenoleakageatthecrankshaft between the crankcase halves or between cylinder and crankcase Replacing the seal on the flywheel side Mod 650 700 Screw down the seal extractor as far as possible in the seal and pull off the seal Lubricate the shaft with oil and fit a new seal Replacing the se...

Страница 62: ... drum must also be dismantled This has a forced fit on the shaft and may be difficult to dismantle without being damaged Use two screwdrivers first to bend out the washer far enough so that extractor 504 90 90 02 can be used Dismantle the seal with an extractor 504 91 40 01 Fit the new seal by means of drift 502 50 82 01 Remove and install the seal ring in the same way as described for changing th...

Страница 63: ...shaft for lubrication of the clutch bearing is not blocked If so clean with compressed air Fit the other parts in the reverse order to dismantling NOTE Remember the spacer sleeve between the clutch drum and crankcase Vibration dampers Mod 650 700 Remove the screws and separate the gripfromtheattachmentinthecrankcase Remove the damper Assembly is conducted in reverse order to dismantling Vibration ...

Страница 64: ...the vibration damper to the grip 3 Insert key 502 50 18 01 in the centre of the vibration damper and unscrew the screw which holds the damper to the cylinder Mod 950 Front vibration damper Dismantle covers air filter and muffler Remove the screws which hold the dam per to the grip and crankcase Remove the vibration damper by the rear handle by removing screws A and one half of the handle B Remove ...

Страница 65: ... the reverse order to dismantling Mod 950 Rear lower vibration damper Remove the starter unit and the screws which hold the damper Mod 950 Rear lower vibration damper Remove the starter unit and the two screws which hold the damper Replace the vibration damper and fit in the reverse order to dismantling Mod 950 Rear upper vibration dam per Unhook the throttle lever at the throttle controlandremove...

Страница 66: ...A which holds the damper to the grip 2 Remove the screws B which hold the grip to the tank unit Unscrew the vibration damper 3 Turn the grip so that the vibration damper can be unscrewed with tool 502 50 66 02 NOTE Make sure that the tool grips both the vibration damper s metal plates Fit new vibration damper in the reverse order to dismantling Mod 1250 Front vibration damper Remove the screws A a...

Страница 67: ...tool 502 50 66 02 4 Remove the screw which holds the lower vibration damper 5 Separate crankcase and tank unit sufficiently to allow tool 502 50 66 02 to be placed over the vibration dam per 6 Unscrew the damper and replace it with a new one NOTE The tool should grip the damper s two metal plates Dismantle the two upper vibration dam pers 7 Dismantle the two upper vibration dampers Insert key No 5...

Страница 68: ...ews Remove all the screws 7 pcs which hold the crankcase halves together Separate the crankcase halves Separate the crankcase halves by means of tool 502 51 61 01 Start with the clutch side half Press out the crankshaft from the crank case half Use the same tool as above and press out the crankshaft from the crankcase half Inspect the crankshaft according to the chapter Inspection of crankshaft ...

Страница 69: ...r arm Clean both crankcase halves Make sure that the two guide pins are not misplaced Carefully scrape off residual gasket from the sealing surfaces Taketheopportunitytoreplacethescrews for the cutter arm if they are worn or damaged Press them out with a hammer and drift Fit new ball bearings and seals Pullthe crankshaftintotheflywheelside s crankcase half Fit new ball bearings and seals Heat up t...

Страница 70: ...10 Tighten all the crankcase screws Push the crankcase halves together and tighten the crankcase screws Check that the crankshaft rotates easily If not tap the shaft journals a few times with a plastic mallet to release any ten sion Lubricate the shaft journals with a few drops of oil and fit the seals The casing should face outwards Use assembly sleeve 505 38 17 23 on the clutch side Check that t...

Страница 71: ... way as described for mod 650 700 Mod 1250 Dismantle the cutter arm Mod 1250 Dismantle all parts so that only the crankcase with crankshaft remain Dismantle the cutter arm by removing the nut A and screws B Mod 950 Remove all screws which hold the crank case halves together Mod 950 Dismantle all parts so that only the crankcase and crankshaft remain Remove all screws 9 items which hold the two cra...

Страница 72: ...ove all screws 9 items which hold the two crankcase halves together Separate and assemble the crankcase halves in the same way as described for mod 650 700 Inspection of crankshaft Check the connecting rod s big end Inspection of crankshaft The crankshaft cannot be renovated and must be replaced by a new one if it is worn or damaged Check the connecting rod s big end If seizure marks or discolouri...

Страница 73: ...the big end bearing There should be no radial play upwards and down wards on the connecting rod It should however have an axial play to ensure good lubrication of the big end bearing Blow clean the channel for the automatic lubrication of the clutch drum s bearing Mod 650 and 700 have automatic lubrication of the clutch drum s bearing Check with compressed air that the lubrication channel is open ...

Страница 74: ...0 700 Crankcase lubrication hole Remove the centrifugal clutch and seal the lubrication hole with tape Model 950 Muffler side Remove the cutting equipment silencer and heat shield plate Put cover wahser No 502 71 39 01 between the silencer and the cylinder Tighten the muffler screws Model 950 Carburettor side Remove the carburettor from the cylinder Fix cover washer No 506 34 45 01 to the inlet pi...

Страница 75: ...2 71 39 01 over the exhaust port Use the muffler attachment screws and nuts together with two spacer sleeves No 502 71 40 01 Model 1250 Carburettor side Remove the carburettor Remove the spacer from the cylinder NOTE Do not force off the plastic component which guides the throttle cable Insert Allen key No 502 50 18 01 through the tapped holes and undo the screws which hold the spacer to the cylin...

Страница 76: ...75 6 Model 1250 Crankcase lubrication hole Remove the centrifugal clutch and seal the lubrication hole in the crankshaft with tape ...

Страница 77: ...76 ...

Страница 78: ...77 Cutting equipment 7 Contents Dismantling mod 650 700 78 Assembly mod 650 700 80 Dismantling mod 950 1250 83 Assembly mod 950 1250 83 ...

Страница 79: ...t the locking mechanism functions in all positions Rectify all faults as soon as they are discovered in order not to compromise user safety Dismantling Mod 650 700 Dismantle the cutter disc Dismantling Mod 650 700 Dismantle the cutter disc Lock the cutter disc by placing a suitable locking pin in the hole in the cutter arm Unscrew and remove the screw support washer and cutter disc Remove hose A i...

Страница 80: ... holds the pulley Lift off the pulley and washer which lies between the ball bearings and pulley Press out the shaft by means of a mandrel and hammer NOTE If only the arbor bush and flange are to be dismantled this can be done by levering with two screw drivers placed between the flange and guard Place a suitable sleeve under the cutter arm and press out the shaft by means of a drift and hammer Li...

Страница 81: ... a hot air gun to approx 150 C and fit a new ball bearing Do not forget the spacer ring between the ball bearings and make sure that they are pressed down well against the shoulder Ifnecessaryfitnewretainingscrewswhile the cutter arm is hot Apply a little grease on the indicating washer A and put in on the guard Thereafter place the thick rubber washer B on the indicating washer and then put on th...

Страница 82: ...d inwards Do not forget the spacer ring against the ball bearings Tighten the screw Drivetheshaftinthroughtheballbearings using a plastic faced hammer until it projects 5 5 mm from the ball bearing on the other side Fit the pulley Place the spacer ring on the ball bearings and then put on the pulley with the welded reinforcement washer turned inwards towards the cutter arm Tighten the screw Fit th...

Страница 83: ...n of a belt after prolonged use Fig B Replace the belt if after a short period of use it shows signs of cracking across the belt even if there is only slight wear on the sides Fig C Worn rough edges on the belt are the result of incorrect contact with the pulley or loose nuts on the cutter arm Fig D Irregularwearresultingfromloose belt or high idling speed Fig E Worn off strips of belt worn reinfo...

Страница 84: ...s rotated then tighten the nuts Dismantling Mod 950 1250 Dismantle the cutter disc belt covers drive belt belt disc support washers and spacer sleeve in the usual way Dismantling Mod 950 1250 Dismantle the cutter disc belt covers drive belt and pulley in the same way as for mod 650 700 TIP If only the spacer sleeve and the inner support washer are to be dismantled this can be done by bending with ...

Страница 85: ... half way Tension the drive belt in the same way as for mod 650 and 700 and then tighten the two screws TIP Install a diamond cutting disc and warm the circular saw up for about 2 minutes Check the belt tension and re tension the belt if necessary Fit the cutter arm Tension as the drive belt at the same time as the cutting disc is rotated and tighten the two nuts ...

Страница 86: ...Tools 8 Contents Clutch 86 Crankshaft 86 Ball bearing 86 Vibration damping 86 Sealing ring 87 Ignition system 88 Pressure testing 88 Cylinder and piston 90 Crankcase 90 Fuel system 90 Workshop equipment 91 ...

Страница 87: ...86 504 90 90 02 8 650 700 950 1250 502 50 49 01 502 50 30 10 502 50 30 08 502 50 66 02 Tools Clutch Model Crankcase Ball bearing Vibration damping ...

Страница 88: ...87 8 504 91 40 01 505 38 17 23 502 50 82 01 650 700 950 1250 502 50 52 01 504 91 28 00 502 50 55 01 Tools Model Sealing ring ...

Страница 89: ...88 8 502 51 34 06 502 51 49 02 650 700 950 1250 0 5 mm 502 71 13 01 502 51 54 01 501 69 17 02 502 54 02 01 Tools Model Ignition system Pressure testing ...

Страница 90: ...89 8 650 700 950 1250 502 50 38 01 502 71 38 01 501 56 27 01 200 0 5 10 15 20 4 0 30 35 25 45 50 55 6 0 100 150 50 0 300 250 350 400 502 71 39 01 502 71 40 01 506 34 45 01 Model Tools Pressure testing ...

Страница 91: ...90 8 650 700 950 1250 502 54 15 01 502 50 70 01 505 38 17 05 502 50 83 01 502 51 61 01 501 60 02 03 Cylinder piston Crankcase Fuel system Tools ...

Страница 92: ...91 502 50 18 01 4 mm 502 50 57 01 3 16 504 90 00 06 504 90 00 01 04 505 38 13 08 8 650 700 950 1250 502 71 14 01 502 50 19 01 3 mm 531 03 16 86 Workshop equipment Model Tools ...

Страница 93: ...64 01 504 90 00 01 505 38 13 08 5 mm 6 mm 8 mm 8 650 700 950 1250 Stl 46 108 07 21 46 48 108 07 21 48 50 108 07 21 50 52 108 07 21 52 54 108 07 21 54 56 108 07 21 56 58 108 07 21 58 Model Tools Workshop equipment ...

Страница 94: ...93 9 Technical data Contents Technical data 94 Tightening torque 94 ...

Страница 95: ...lywheel ignition module mm 0 3 0 5 0 3 0 5 0 3 0 5 0 3 0 5 Carburettor manufacture Tillotson Tillotson Tillotson Walbro Carburettor type HS175F HS175F HS282A WG9 Carburettor setting L 1 1 4 1 1 4 1 1 4 1 1 4 Carburettor setting H 7 8 7 8 3 4 Fuel tank litres 0 7 0 7 1 0 1 25 Weight kg 9 4 300 mm 10 0 350 mm 9 9 300 mm 13 7 350 mm Sound level dBA 101 101 103 103 Disc diameter mm 300 350 300 350 400...

Страница 96: ...108 07 07 47 Teknik Info AB Huskv 2 0106 SEK 95 ...

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