Zenoah GZ3500T Workshop Manual

Chain saw

Workshop Manual

April 2009

Instruction

This maintenance manual gives special explanation to maintenance standards, procedures,

and the main causes of malfunction.

This manual also includes many common customer inquiry items. Please make use of this

manual for maintenance work and supplement this manual by your rich the experience and

judgment you already possess.

“WARNING”

1. The contents of this manual are based on specifications as of January 2009.

The contents may be modified due to performance improvement or some other reason

without notice.

2. Use Zenoah brand-name parts when replacing a part during maintenance, etc.

The manufacturer does not bear any responsibility if trouble occurs during parts use of

other than brand-name parts.

3. Read this manual thoroughly before beginning the maintenance work, understand it,

apply the content to the actual maintenance tasks and guide the customer if directions,

are needed.

Contents

Strato-charged Engine

1. Outline ............................................................................................................... 1

2. Operating Principle ............................................................................................. 2

Construction

1. Engine Short Block Parts ................................................................................... 3

2. Recoil and Clutch Parts ...................................................................................... 4

3. Right Handle and Carburetor Parts .................................................................... 5

4. Chain Brake Parts .............................................................................................. 6

Specifications and Technical Data

.................................................................... 7

Service Guide

1. Teardown

1-1 Carburetor Removal .................................................................................... 8

1-2 Recoil Assy. Removal .................................................................................. 9

1-3 Handle Comp. Removal .............................................................................. 9

1-4 Spark Plug Removal .................................................................................. 10

1-5 Rotor Removal .......................................................................................... 10

1-6 Module Removal ....................................................................................... 10

1-7 Clutch Removal ......................................................................................... 11

1-8 Oil Pump Removal .................................................................................... 11

1-9 Inlet Pipe Removal .................................................................................... 12

1-10 Muffler Removal ...................................................................................... 12

1-11 Engine Short Block Removal ................................................................... 13

1-12 Crank Shaft Removal .............................................................................. 14

2 Reassembly

2-1 Engine Short Block Assembly .................................................................... 15

2-2 Heat-resistant Gasket Assembly ............................................................... 16

2-3 Inlet Pipe Assembly ................................................................................... 16

2-4 Worm Gear Assembly ............................................................................... 17

2-5 Clutch Assembly ........................................................................................ 17

2-6 Rotor Assembly ......................................................................................... 17

2-7 Module Assembly ...................................................................................... 18

2-8 Handle Comp. Assembly ........................................................................... 18

2-9 Switch Cord and Earth Cord Wiring ........................................................... 19

2-10 Carburetor Assembly ............................................................................... 20

2-11 Fan Cover Assembly ............................................................................... 20

Carburetor

1. Specifications

1-1 Carburetor Specifications .......................................................................... 21

1-2 Recommended Tools ................................................................................. 21

1-3 Construction .............................................................................................. 22

1-4 Carburetor Conforms to Exhaust Emissions Regulations .......................... 23

2. Carburetor Adjustment

2-1 Required Tools and Parts .......................................................................... 24

2-2 Pre Adjustment Check List ........................................................................ 24

2-3 Adjustment ................................................................................................ 24

1

Strato-charged Engine

1. Outline

Unlike the conventional 2-cycle engine scavenging system, the Strato-charged Engine

(

※

1)

scavenges burnt

gas by the stratified lead air scavenging method.

By creating a stratified air layer between burnt gas and the air-fuel mixture, this system significantly reduces

exhaust of unburned air-fuel mixture.

(※1)

Strato is a coined word derived from “stratified” (e.g. stratified layer of air / gas), and ”stratosphere”, which

conjures up the image of purity and calm.

Air Valve

Carburetor

Throttle Valve

Inlet pipe

Manifold

Cleaner element

Piston

Lead Air

Air-fuel Mixture

2

Strato-charged Engine

2. Operating Principle

1. As the piston proceeds through the upstroke of the

intake cycle, the crankcase vacuum sucks the lead

air in through the scavenging port via the groove on

the piston skirt.

2. As the piston begins its down stroke after top dead

center, a scavenging port starts to open and lead

air in the scavenging port moves into the cylinder

earlier than the air-fuel mixture.

3. As the piston begins its to upstroke after bottom

dead center, burnt gas in the cylinder is pushed out

through the exhaust port by lead air. Therefore,

almost no air-fuel mixture is emitted.

Carburetor

Lead Air

Scavenging Port

Grooved Piston

Air-fuel Mixture

Burnt Gas

Exhaust Port

Air-fuel Mixture

Lead Air

Exhaust Port

Burnt Gas

Air-fuel Mixture

Lead Air

3

Construction

1. Engine Short Block Parts

Screw TP5x 19L

(Precoat thread lock screw)

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Chain Catcher

Under Guard

Muffler

Gasket

Spark Arrester

Muffler Guide

Engine Case

Nut M5 (2)

Torque: 5.9～

～～

～7.8 N・

・・

・m

(0.6～

～～

～0.8 kgf・

・・

・m)

Cylinder

Piston Ring

Bolt

Snap Ring

Piston

Thrust Washer

Piston Pin

Needle Bearing

Crankshaft Comp.

Main Bearing

Oil Seal

Snap Ring

Oil Seal

Bumper

Screw M4x 10L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Apply thread lock: #1342

Exhaust Pipe

Top Cover

Bolt M5x 14L (3)

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

Bolt M5x 14L (2)

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

Bolt M4x 10L (4)

Torque: 1.5～

～～

～2.5 N・

・・

・m

(0.15～

～～

～0.25 kgf・

・・

・m)

Bolt M5x 20L (4)

Torque: 6.9～

～～

～8.8 N・

・・

・m

(0.7～

～～

～0.9kgf・

・・

・m)

Gasket

TR, Cover TPO

Apply liquid gasket: #1217F

TR, Cover MAG

Apply liquid gasket: #1217F

Crank Case

Bolt M5x 20L

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

Screw TP5x 19L

(Precoat thread lock screw)

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Bolt M4x 10L (4)

Torque: 1.5～

～～

～2.5 N・

・・

・m

(0.15～

～～

～0.25 kgf・

・・

・m)

Bolt M5x 14L

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

EU: Option

4

Construction

2. Recoil and Clutch Parts

Thrust Washer

Oil Pipe (suction side)

Oil Pump

Bolt M4x 14L (2)

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Pump Cover

Worm Gear

Needle Bearing

Plate

Bolt M5x 14L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Apply thread lock:

Threebond #1322 or

Loctite #262

Oil Pipe

(discharge side)

Clutch Drum

Clutch 13mm

Torque: Three Tightening Step

27.4→

→→

→19.6→

→→

→23.5 N・

・・

・m

(2.8→

→→

→2.0→

→→

→2.4 kgf・

・・

・m)

Clutch Spring

Label, Recoil

Screw TP5x 19L (4)

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Rope

Knob

Spiral Spring

Reel

Spring

Screw

Fan Cover

DF Guide

Nut M8

Torque: 14.7～

～～

～18.6 N・

・・

・m

(1.5～

～～

～1.9 kgf・

・・

・m)

Rotor Assy.

Bolt M4x 20L (2)

Torque: 2.9～

～～

～4.9 N・

・・

・m

(0.3～

～～

～0.5 kgf・

・・

・m)

Apply thread lock:

Threebond #1342 or

Loctite #242

Ratchet Pulley

Terminal

Coil Comp.

Spring

Plug Cap

Spacer

Screw TP5x 19L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Plug Cover

Sparkplug M10 (CMR7H)

Torque: 8.8～

～～

～12.8 N・

・・

・m

(0.9～

～～

～1.3 kgf・

・・

・m)

Starter Case

5

Construction

3. Right Handle and Carburetor Parts

Left Handle

Oil Tank Cap

Gasket

Air Pipe

Gasket

Fuel Tank Cap

Elbow

Label, Caution

Front Spring

Screw TP5x 19L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Screw M5x 20L

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

Stopper Bolt TP5.4x 16L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

PTO Spring

Air Cleaner Cover

Knob

Air Cleaner Element

Seal

Carburetor Guide

Seal

Carburetor

Seal

Bolt M5x 45 (2)

Torque: 3.4±

±±

±0.2 M・

・・

・m

(0.35±

±±

±0.02 kgf・

・・

・m)

Apply thread lock:

Threebond #1342 or

Loctite #242

Manifold

Fuel Pipe

Fuel Filter

Grommet

Breather

Primer Pump

Knob Bracket

V

alve

Seal

Spring

Throttle Lever

Throttle Rod

Safety Lever

Switch Cord

Earth Cord

Grip Cover

Screw TP5x 19L (2)

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Switch

Pipe

Joint

Oil Filter Pipe

Joint

Pipe

Oil Filter

Damper Spring

Band

Handle Comp.

Screw TP5x 19L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Screw TP5x 19L

Torque: 2.0～

～～

～2.9 N・

・・

・m

(0.2～

～～

～0.3 kgf・

・・

・m)

Hook

(USA)

Screw TP5x 20L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Screw TP5x 19L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Inlet Pipe

Bolt M5x 12L (2)

Torque: 5.9～

～～

～7.8 N・

・・

・m

(0.6～

～～

～0.8 kgf・

・・

・m)

Apply thread lock:

Threebond #1342 or

Loctite #242

Screw TP5x 19L

Torque: 2.5～

～～

～3.9 N・

・・

・m

(0.25～

～～

～0.4 kgf・

・・

・m)

Plate, Hook

Hook

(EU)

6

Construction

4. Chain Brake Parts

Spring Cover

Brake Band

Brake Spring

Chain Cover

Nut

Tensioning Screw

Tensioning Gear

Outer Plate

Slide Arm

Roller

Label, Cover

Spring

Tensioning Nut

Spring

Roller

Washer

Spring

Spacer

Screw

Inertia Weight

Nut

Torque: 1.9～

～～

～2.9 N・

・・

・m

(0.2～

～～

～0.3 kgf・

・・

・m)

Brake Lever

Spacer

Front Handle Guard

Screw TP4x 12L (2)

Torque: 0.7～

～～

～1.5 N・

・・

・m

(0.07～

～～

～0.15 kgf・

・・

・m)

Screw TP4x 12L (2)

Torque: 0.7～

～～

～1.5 N・

・・

・m

(0.07～

～～

～0.15 kgf・

・・

・m)

Stud Bolt

Inner Plate

Bolt M5x 12L

Torque: 4.9～

～～

～7.8 N・

・・

・m

(0.5～

～～

～0.8 kgf・

・・

・m)

7

Specifications and Technical Data

Item Unit Specifications

Model T GZ3500T

Engine type Air cooled 2-stroke single cylinder piston valve gasoline engine

Cylinder bore×stroke mm (in.) φ40×28 (1.58×1.10)

Displacement Cm

3

35.2

Effective compression ratio 7.4

Fuel Fuel-oil mixture Mixing ratio

・ Zenoah genuine 2-cycle oil 50: 1

・ 2-cycle oil available on market 25: 1

Type Diaphragm type butterfly throttle valve

Carburetor

Model Walbro WT-935

Starting method Recoil starter

Engine lubrication Fuel-oil mixture

Ignition system CDI with automatic timing advance system

Spark plug NGK CMR7H

Stopping method Primary coil short-circuiting

Cooling system Forced air cooling

Air cleaner Dry type

Output axle rotation direction Clockwise (View from output axle)

Clutch type Centrifugal clutch (Sintered metal clutch shoe)

Chain oil Zenoah genuine chain oil or Engine oil SAE #10-30

Lubricating method Automatic lubrication

Oil pump type Mechanical oil pump with discharge adjustment

Type Sprocket nose bar

Guide bar

Length mm (in.) 300 (12) 350 (14)

Saw chain 91VG Links 45 52

Anti-vibration mechanism Three-points mount

Throttle type With safety lock

Chain brake Auto activation band type

Safety guard With left-hand guard

Overall dimensions

(Length×Width×Height)

mm (in.) 290×235×230 (11.4×9.25×9.06)

Dry weight (Power unit only) kg (lb) 3.3 (7.3)

Fuel tank capacity cm

3

245

Oil tank capacity cm

3

170

Operating speed rpm 7000～12500

Idling speed range rpm 2900 ±200

Clutch engaging speed range rpm 4200 ±300

Full load fuel consumption L/ h/ rpm 0.95/ 9000

Chain oil discharge level cm

3

/ min 3～9 Variable/ 8000

Maximum output kW (PS)/ rpm 1.45 (1.97)/ 9000

Maximum torque N･m (kgf･m)/ rpm 1.57 (0.16)/ 6500

8

Service Guide

1. Teardown

●

●●

● Empty the fuel tank before starting the work to prevent leaking of composite fuel (if any).

●

●●

● Empty the oil tank before starting the work to prevent leaking of chain oil (if any) from the

tank.

Remove the chain cover, the guide bar, the saw chain, and the air cleaner cover from the engine body.

1-1 Carburetor Removal

1. Remove the mounting Bolts, hold the body of the

cleaner element and remove the manifold and the

cleaner element.

Make sure the seal remains attached to the cleaner

element.

2. Remove the other carburetor mounting screw.

Do not try to demount the carburetor yet.

If you try, the throttle rod will be bent.

3. Remove the mounting screws of the right handle

and lift up the grip cover.

4. Lift up the carburetor, and pull out the fuel hose.

5. Pull out the throttle rod from the throttle lever, and

remove the carburetor.

The carburetor guide comes off and be

careful not to lose it.

CAUTION

Mounting Screw (2)

TP5x 19L (T27)

Grip Cover

Throttle Rod

Carburetor

Guide

Throttle Lever

Fuel Hose

Mounting Bolt (2)

M5x 45L (T27)

Carburetor

Mounting Screw

TP5x 20L (T27)

Seal

Manifold

Cleaner element

9

Service Guide

1-2 Recoil Assy. Removal

1. Remove the mounting screws of the recoil assy.

and demount the recoil assy.

2. Remove the fan cover.

The DF guide comes off and be careful not to

lose it.

1-3 Handle Comp. Removal

1. Pull and remove the switch cord and the earth cord by hand.

2. Remove the mounting bolts of the front spring and PTO spring.

3. Remove the Inlet pipe and the air pipe from the handle comp.

For easy removal, push the right handle with your weight. The pipe rises and can be easily removed.

4. Pull out the oil pipe, and separation the engine case and the handle comp.

CAUTION

Mounting Screw (4)

TP5x 19L (T27)

Fan Cover

DF Guide

Recoil Assy.

Mounting Screw

M5x 20L (T27)

Mounting Screw

TP5x 16L (T27)

1.

PTO Spring

Switch Code

Earth Code

Front Spring

Push the right handle with your weight.

Oil Pipe

Handle Comp.

Inlet Pipe

(Mixture Side)

Inlet Pipe

(Lead Air Side)

Air Pipe

2.

3.

4.

Engine Case

10

Service Guide

1-4 Spark Plug Removal

1. Remove the mounting screw, then remove the plug

cover.

2. Remove the plug cap, then remove the spark plug.

3. Set the stopper (special tool: 4810-96220) into the

plug hole.

1-5 Rotor Removal

Remove the mounting nut using the box spanner, then

remove the rotor.

1-6 Module Removal

Remove the mounting bolts, then remove the module.

Mounting Nut

M8 (12 mm)

Box Spanner

(12mm)

Rotor

Mounting Bolt (2)

M4x 20L (T27)

Spacer

Terminal

Module

Mounting Screw

TP5x 19L (T27)

Spark Plug

(M10)

Plug Cap

Stopper

Plug Cover

11

Service Guide

1-7 Clutch Removal

Remove the clutch using the box spanner, and remove the plate, clutch drum and the needle bearing.

1-8 Oil Pump Removal

1. Remove the worm gear and the washer.

2. Remove the mounting bolt, then remove the pump cover.

3. Remove the mounting bolts, and disconnect the oil pipe then remove the oil pump.

4. Remove the mounting bolt, then remove the inner plate.

Clutch

(counterclockwise threading)

Box Spanner

(13mm)

Plate

Needle Bearing

Clutch Drum

Mounting Bolt

M5x 14L (T27)

Mounting Bolt (2)

M4x 14L (T27)

Mounting Bolt

M5x 12L (T27)

Oil Pump

Pump Cover

Washer

Inner Plate

Worm Gear

Oil Pipe (discharge side)

12

Service Guide

1-9 Inlet Pipe Removal

Remove the mounting bolts, then remove the inlet

pipe.

1-10 Muffler Removal

1. Remove the mounting screw, then remove the

chain catcher.

The catcher and the under guard are tightened

together.

2. Slide the under guard and remove it from the

casing.

3. Remove the mounting bolts and the mounting nuts

using the box spanner, then remove the muffler.

The engine casing contains a heat-resistant

gasket. You need not remove it, but if it

comes off, be sure to remount it.

CAUTION

Mounting Bolt (2)

M5x 12L (T27)

Inlet Pipe

Mounting Screw

TP5x 19L (T27)

Under Guard

Chain Catcher

Mounting Nut

M5 (8 mm)

Mounting Bolt (2)

M5x 14L (T27)

Box Spanner

(8mm)

Muffler

Heat-resistant Gasket

13

Service Guide

1-11 Engine Short Block Removal

1. PTO side:

Remove the mounting bolts and the screw.

2. MAG side:

Remove the mounting bolts, and pull up the top

cover from the engine case.

3. Detach the short block from the engine case.

Mounting Bolt (2)

M5x 14L (T27)

Mounting Screw

TP5x 19L (T27)

PTO side

Mounting Bolt (2)

M5x 14L (T27)

Top Cover

MAG side

Engine Short Block

Engine Case

Heat-Resistant Gasket

14

Service Guide

1-12 Crank Shaft Removal

1. Remove the mounting bolts, then remove the crank

case.

2. Pull out the piston from the cylinder, and separate

the oil seals and snap ring.

If necessary, remove the main bearings.

3. Remove the snap rings and pull out the piston pin,

then remove the piston.

If necessary, remove the thrust washers and the

needle bearing from the connecting rod.

Mounting Bolt (4)

M5x 20L (T27)

Cylinder

Crank Case

Main Bearing

Oil Seal

Piston

Cylinder

Oil Seal

Snap Ring

Piston

Snap Ring

Piston Pin

Thrust Washer

Needle Bearing

Crank Shaft

Thrust Washer

Snap Ring

Connecting Rod

15

Service Guide

2 Reassembly

Reassemble the chain saw in the reverse order of teardown, and note these items.

2-1 Engine Short Block Assembly

● Apply 2T oil to the main bearing, smaller-end (needle) bearing, piston, inside of the cylinder, the space

between the weight and the bearing.

Degrease surface of the bearing and crank case ID at bearing area ( area).

● Make sure to point the recessed mark (arrow) on

the piston head to the exhaust (muffler) side.

● Fit the snap ring in the groove firmly and position

the end gap of the snap ring 90 degree the notch.

・

・・

・ If the snap ring is poorly inserted or the end

gap of the snap ring is incorrectly

positioned, the snap ring may comes off

during engine operation resulting in

damage to the engine.

・

・・

・ Never reuse a snap ring. Always insert a

new one.

● Apply grease to the lip area of the oil seal.

Degrease surfaces of the oil seal.

CAUTION

Piston

OK NG

Snap Ring Direction

Arrow Mark

Exhaust Side

End Gap

Bolt (4) M5x 20L (T27)

Torque: 6.9～

～～

～8.8 N・

・・

・m

(0.7～

～～

～0.9kgf・

・・

・m)

MAG side

Crank Case

Snap Ring

Oil Seal

Piston

Piston Pin

Thrust Washer

Oil Seal

Needle Bearing

Snap Ring

Cylinder

: Inside

: Between the weight

and the bearing

PTO side

Main Bearing

: ID

Main Bearing

2T: 2-cycle Engine Oil

: ID

16

Service Guide

● Apply liquid gasket to the crank case.

Liquid Gasket: Threebond #1217F

● Match the end surface of the oil seal with the end

surface of the crank casing (to prevent interference

with the main bearing) when reassembling the oil

seal in the MAG side.

・

・・

・ Be careful not to move the oil seal too

much. If done, the oil seal may interfere with

the rotor.

・

・・

・ Degrease the shaft if it has any grease on it.

(Otherwise, the rotor may be broken.)

2-2 Heat-resistant Gasket Assembly

Remount the heat-resistant gasket prior to the muffler.

For easy remounting, first set the engine side of the

gasket, bend the opposite side, and then set.

2-3 Inlet Pipe Assembly

Apply liquid gasket to the suction side of cylinder.

Liquid Gasket: Threebond #1217F

Do not apply liquid gasket to areas near the

pulse hole.

If done, the pulse hole may be choked.

CAUTION

Heat-resistant Gasket

Oil Seal

Match the end surface of the

oil seal with the end surface

of the crank casing.

Gap

Bearing

MAG side

Do not apply liquid gasket to

areas near the pulse hole.

17

Service Guide

2-4 Worm Gear Assembly

Apply grease to the worm gear and the shaft.

2-5 Clutch Assembly

● Direct the chamfering portion of the plate to the

engine side.

● Apply loads to the clutch in the order of 27.4, 19.6,

and 23.5 N.m in three stages (to prevent

loosening).

Degrease the screw portion of the shaft to

prevent over-tightening.

2-6 Rotor Assembly

Fit the key of the magnet to the keyway of the crank

shaft when re-assembling the magnet.

Degrease screw portions and the tapered

portion of the shaft.

CAUTION

Rotor

Crank Shaft

Key

Keyway

27.4 N・

・・

・m

(2.79 kgf・

・・

・m)

Clutch

19.6 N

・

・・

・

m

(2.00 kgf・

・・

・m)

23.5 N・

・・

・m

(2.40 kgf・

・・

・m)

Plate

Chamfering

portion

Engine Side

Washer

Crank Shaft

Worm Gear

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Zenoah GZ3500T Workshop Manual

Zenoah GZ3500T Workshop Manual

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