CHICAGO 95497 Assembly And Operating Instructions Manual

Brand: CHICAGO

Model: 95497

Category: Power chainsaws

Type: Assembly And Operating Instructions Manual

GAS CHAIN SAW

18” - 45cc

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Do to continuing improvements, actual product may differ slightly from the product described herein.

You do not operate the Chain Saw with the proper 25:1 fuel mix in its fuel tank.

Never run the Engine with an improper fuel mix, low or no fuel mix.

Running the Engine with an improper fuel mix, low or no fuel mix, will permanently damage the unit.

CAUTION!

Your Warranty Is Voided If:

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

Model 95497

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

PRODUCT SPECIFICATIONS

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, operating,

inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep

your invoice with this manual. Write the invoice number on the inside of the front cover.

Keep this manual and invoice in a safe and dry place for future reference.

GENERAL SAFETY RULES AND PRECAUTIONS

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and dark areas

invite accidents.

2. Do not operate power tools in explosive atmospheres, such as in the

presence of flammable liquids, gases, or dust. Power tools create

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 2

The Emission Control System for this product’s engine is warranted for standards set by the U.S.

Environmental Protection Agency. For warranty information, refer to the last pages of this manual.

This product requires a 25:1 ratio of fuel and 2-cycle oil to be added to its fuel tank before starting.

Attempting to start the Engine with an improper fuel mix, low or no fuel mix WILL ruin the Engine and

void the warranty.

The Engine’s Carburetor may need to be adjusted by a qualified mechanic for efficient high-altitude

use.

Item Description

Engine Specifications Starting Method: Pull Start

Fuel Required: 25:1 Unleaded Fuel & 2 Cycle Oil Mixture

45cc / Engine Power: 1.6 kw / 3600 RPM / 1500 Watts

Maximum Speed: Idle to 2800 RPM

Fuel Tank Capacity: 18.6 Ounces

Spark Plug Type: Champion® RCJ-6Y / Spark Plug Gap: 0.025”

EPA Approved

Saw Chain

Type: 18” Oregon®, Raker, Low Kickback Chain

Saw Chain Pitch: 0.325” / Saw Chain Gauge: 0.058”

Chain Oiler: Automatic / Oil Tank Capacity: 8.8 Ounces / Chain Oil Type: S.A.E. 10W – 30W

Chain Brake: Built Into Front Handle Lever / Saw Sprocket: 7 Tooth x 0.325”

Handle Completely Enclosed “D” Type

Top Angle Plate 30°

Side Plate Angle 85°to 90°

Bar Length 18”

Net Weight 15.35 Pounds

PERSONAL SAFETY

1. Stay alert. Watch what you are doing, and use common sense when

operating a power tool. Do not use a power tool while tired or under the

influence of drugs, alcohol, or medication. A moment of inattention while

operating power tools may result in serious personal injury.

2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair.

Keep your hair, clothing, and gloves away from moving parts. Loose

clothes, jewelry, or long hair can be caught in moving parts.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 3

3. Avoid accidental starting. Be sure the Stop Switch (75A) is in its “STOP”

position and the spark plug is disconnected before moving the Chain Saw

and

before performing any service, maintenance, or cleaning procedures on

the unit.

4. Remove adjusting keys or wrenches before turning the Chain Saw on.

A wrench or a key that is left attached to a rotating part of the machine may

result in personal injury.

5. Do not overreach. Keep proper footing and balance at all times. Proper

footing and balance enables better control of the power tool in unexpected

situations.

TOOL USE AND CARE

1. Do not force the tool. Use the correct tool for your application. The correct

tool will do the job better and safer at the rate for which it is designed.

2. Do not use the Chain Saw if the Stop Switch (75A) does not turn it on or

off. Any tool that cannot be controlled with its Stop Switch is dangerous and

must be replaced.

3. Store idle tools out of reach of children and other untrained persons. Tools

are dangerous in the hands of untrained users.

4. Maintain tools with care. Properly maintained tools are less likely to malfunction

and are easier to control. Do not use a damaged tool. Tag damaged tools

“Do not use” until repaired.

3. Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Provide barriers or shields as

needed. Children should never be in or around the work area.

sparks which may ignite the dust or fumes.

any other condition that may affect the tool’s operation. If damaged, have

the tool serviced before using. Many accidents are caused by poorly

maintained tools.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 4

6. Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one tool may become hazardous

when used on another tool.

SERVICE

1. Tool service must be performed only by qualified repair personnel. Service

or maintenance performed by unqualified personnel could result in a risk of injury.

2. When servicing a tool, use only identical replacement parts. Follow

instructions in the

“Inspection, Maintenance, And Cleaning”

section of this

manual. Use of unauthorized parts or failure to follow maintenance instructions

may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES AND PRECAUTIONS

1. IMPORTANT! Your Warranty is voided if:

You do not operate the Chain Saw with the proper 25:1 fuel mix in its

fuel tank. Never run the Engine with an improper fuel mix, low or no fuel mix.

Running the Engine with an improper fuel mix, low or no fuel mix, will

permanently damage the unit.

2. Maintain labels and nameplates on the Chain Saw. These carry important

information. If unreadable or missing, contact Harbor Freight Tools for a

replacement.

5. Check for misalignment or binding of moving parts, breakage of parts, and

WARNING! Always wear safety equipment. When operating

the Chain Saw, always wear ANSI approved safety impact eye

goggles, hearing protection, heavy duty work gloves, sturdy work

boots, and head protection.

4. Never leave the Chain Saw unattended when it is running. Turn off the

Engine before leaving.

5. Do not allow children and other unauthorized people to handle or play with

the Chain Saw. Children should be kept out of the work area. Also, store the

Chain Saw (with spark plug removed) in a location out of reach of children.

6. Always plan carefully where a tree limb will fall to avoid damage to property

and/or personal injury.

7. Never stand directly beneath the limb you are cutting. Always stand well off

to the side.

8. Do not use the Chain Saw to cut anything except tree limbs and brush.

9. Always maintain a firm grip on the Chain Saw with both hands.

10. Branch trimming is a dangerous activity. The use of this Chain Saw requires

that you be in good physical condition, and with good balance and coordination.

If you are in doubt about the safety issues involved, have a qualified, certified,

arborist/tree surgeon do the work for you.

11. Always keep hands, fingers, and body a safe distance away from the moving

Chain.

12. Do not use the Chain Saw if the Chain is dull.

13. Make sure the wood being cut does not contain foreign materials such as

nails, spikes, etc.

14. WARNING! Ladders are inherently dangerous. NEVER use a ladder

when using the Chain Saw.

KICKBACK PRECAUTIONS

1. Kickback is a dangerous reaction that can lead to serious injury. Kickback

may occur when the moving Chain contacts an object at the upper portion of the

tip of the Guide Bar or when the wood closes in and pinches the Saw Chain in

the cut.

Contact at the upper portion of the tip of the Guide Bar can cause the Chain to

dig into the wood and stop the Chain for an instant. The result is a quick, reverse

reaction which kicks the Guide Bar up and back toward the operator. If the

Chain is pinched along the top of the Guide Bar, the Guide Bar can be driven

rapidly back toward the operator. Either of these reactions can cause loss of

Chain Saw control which can result in serious injury.

Do not merely rely only upon the safety devices built into the Chain Saw. As an

operator, you should take several steps to keep the cutting job free from accident

or injury:

A. Make sure the area in which you are cutting is free from obstructions. Do

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 5

not allow the nose of the Guide Bar to contact a log, branch, fence, or any

other obstruction while you are operating the tool.

B. Always cut with the Engine running at full speed. Fully squeeze the Throttle

and maintain a steady cutting speed.

C. Always keep the Chain clean and sharp.

D. Keep all guards and safety devices in proper working order and properly

adjusted.

E. Never use the Chain Saw on a ladder or unstable support.

F. Before starting the Engine, make sure the Chain is not contacting any object.

G. Shut off the Engine, and make sure the Chain has stopped before setting the

tool down.

ELECTRICAL PRECAUTIONS

1. To protect yourself from electrocution, do not operate the Chain Saw

within 50 feet of any overhead electrical lines.

2. NEVER use the Chain Saw in damp or wet conditions.

CARBON MONOXIDE PRECAUTIONS

1. WARNING! This Chain Saw is designed for outdoor use only. Do

not operate the Chain Saw in a closed area or in a poorly ventilated area.

When running, the Engine of this product produces carbon monoxide, a

colorless, odorless, toxic gas that, when inhaled, can cause serious

personal injury or death.

FIRE AND EXPLOSION PRECAUTIONS

1. Gasoline fuel and fumes are flammable, and potentially explosive.

Use proper fuel storage and handling procedures. Always have multiple

ABC class fire extinguishers nearby.

2. Keep the Chain Saw and surrounding areas clean at all times.

3. When spills of fuel or oil occur, they must be cleaned up immediately.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 6

Dispose of fluids and cleaning materials as per any local, state, or federal codes

and regulations. Store oil rags in a covered metal container.

4. Never store fuel or other flammable materials near the Chain Saw.

5. Do not smoke, or allow sparks, flames, or other sources of ignition around

the Chain Saw.

6. Keep grounded conductive objects, such as tools, away from exposed, live

electrical parts and connections to avoid sparking or arcing. These events

could ignite fumes or vapors.

7. Do not refill the Fuel Tank while the Engine is running or while the Engine is

still hot. Do not operate the Chain Saw with known leaks in the fuel system.

8. Use only Engine manufacturer recommended fuel and oil.

MECHANICAL PRECAUTIONS

1. Prior to performing service, maintenance, or cleaning procedures, always

make sure the Stop Switch (75A) is in its “STOP” position. Allow the Engine

to completely cool. Then, remove the spark plug from the Engine.

2. Do not alter or adjust any part of the Chain Saw or Engine that is

assembled and supplied by the manufacturer.

3. Always follow and complete scheduled Chain Saw and Engine

maintenance.

CHEMICAL PRECAUTIONS

1. Avoid contact with hot fuel, oil, exhaust fumes, and solid surfaces.

2. Avoid body contact with fuels, oils, and lubricants used in the Chain Saw

and Engine. If swallowed, seek medical treatment immediately. Do not

induce vomiting if fuel is swallowed. For skin contact, immediately wash with

soap and water. For eye contact, immediately flush eyes with clean water.

1. Prolonged exposure to high noise levels is hazardous to hearing.

Always wear ANSI approved hearing protection when operating or working

NOISE PRECAUTIONS

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 7

around the Chain Saw when it is running.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 8

MISC. PRECAUTIONS

1. DANGER! We recommend that people with pacemakers not use this tool.

This tool produces strong electromagnetic fields that can cause interference to or

failure of the pacemaker. People with pacemakers should consult their

physician(s) for advice.

2. WARNING! The warnings and precautions discussed in this manual cannot

cover all possible conditions and situations that may occur. It must be under-

stood by the operator that common sense and caution are factors which cannot

be built into this product, but must be supplied by the operator.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts Lists on pages 17

and 19 are included. If any parts are missing or broken, please call Harbor Freight Tools

at the number shown on the cover of this manual as soon as possible.

PRODUCT FEATURES

75A

FIGURE A

Chain Brake (28) Stop Switch (75A) Trigger Lock (58)

Starter Handle (44) Fuel Tank Cap (57) Rear Handle (22)

Air Filter Cover (33) Oil Tank Cap (52) Trigger (64)

Choke Lever (65) Front Handle (74) Saw Chain (77)

Trigger Lockout Button (62) Guide Bar (76)

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 9

ASSEMBLY INSTRUCTIONS

To Install The Guide Bar And Saw Chain:

1. CAUTION! The Saw Chain (77) has very sharp edges. Make sure to wear

heavy duty work gloves for safety. (See Figure B.)

2. Pull the Chain Brake (28) towards the Front Handle (74) to make sure the Brake

is not

on. (See Figure B.)

3. Unscrew the two Nuts (30). Then remove the Cover Plate (52A) to expose the

Clutch Shell (49A) and Sprocket (50A). (See Figure B.)

4. The Guide Bar (76) contains a shaft slot that fits over the Shafts (66). The

Guide Bar also has two Chain Tensioning Pin Holes which fit over the two Shield

Pins (2). Place the Guide Bar onto the Shafts so that the Shield Pins fit into the

two Chain Tensioning Pin Holes. (See Figure B.)

5. Fit the Saw Chain (77) over the Sprocket (50A) and into the Guide Bar (76)

groove. The Saw Chain cutters on the top of the Guide Bar should face

toward the tip of the Guide Bar, in the direction of the chain rotation.

(See Figure B.)

6. Replace the Cover Plate (52A) and secure with the two Nuts (30). Tighten the

two Nuts finger tight only to allow for tension adjustment. (See Figure B.)

7. The Saw Chain (77) is properly tensioned when there is no slack on the under-

FIGURE B

SAW CHAIN

(77)

COVER PLATE

(52A)

NUTS

(30)

CLUTCH SHELL (49A)

SPROCKET (50A)-hidden behind 49A

SHAFTS

(66)

CHAIN TENSIONING

PIN HOLES

GUIDE BAR

(76)

CHAIN BRAKE

(28)

CHAIN DIRECTION

side of the Guide Bar (76). The Chain should be snug, but should turn by hand

without binding. To adjust the tension of the Chain, turn the Tensioning Screw

(12) clockwise, making sure the Chain seats into the Bar Guide groove during

tensioning. Lift the tip of the Bar Guide up to check for sag. Release the tip of

the Bar Guide, and turn the Tensioning Screw 1/2 turn clockwise. Repeat this

process until sag does not exist. Then, firmly retighten the Nuts (30).

(See Figure B.)

8. NOTE: If the Chain is too tight, it will not rotate. Loosen the Nuts slightly and

turn the Tensioning Screw 1/4 turn counterclockwise. Lift the tip of the Bar

Guide up to check for proper tension. Then retighten the Nuts.

(See Figure B.)

9. IMPORTANT: Adjust the Saw Chain (77) tension only when the Chain is cold.

Chain tensioning while warm may be too tight upon cooling. A new Chain will

expand its length in the beginning of use. Check and readjust the tension

frequently, as a loose Chain can derail or cause rapid wear of itself and the Guide

Bar (76). (See Figure B.)

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 10

PRE-START INSTRUCTIONS

To Fill The Chain Oil Tank:

1. Prior to each use of the Chain Saw, the Chain Oil Tank must be filled with S.A.E.

10W-30W motor oil (approximately 8.8 ounces). Do not use old or regenerated

oil as that can damage the oil pump. (See Figure C.)

2. To fill the Oil Tank, turn the Chain Saw on its side with its Oil Tank Cap (52) facing

up. Unscrew and remove the Oil Tank Cap. Then fill the Oil Tank completely.

Once filled, replace the Oil Tank Cap and set the Chain Saw upright.

(See Figure C.)

3. NOTE: The chain oil

flow

can be changed by inserting a screwdriver in the hole

on the bottom of the clutch side of the Chain Saw. Turn the Screw within the

hole clockwise for less oil flow or counterclockwise for more oil flow.

OIL TANK CAP (52)

FIGURE C

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 11

To Fill The Fuel Tank:

1. IMPORTANT! Your warranty is voided if:

You do not operate the Chain Saw with the proper 25:1 fuel mix in its

Fuel Tank. Never run the Engine with an improper fuel mix, low or no fuel mix.

Running the Engine with an improper fuel mix, low or no fuel mix will

permanently damage the unit. (See Figure D.)

4. WARNING! NEVER attempt to fill the Fuel Tank when the Engine is running

or hot to the touch.

OPERATING INSTRUCTIONS

The Chain Brake:

1. WARNING! Always wear safety equipment. When operating the Chain

Saw, always wear ANSI approved safety impact eye goggles, hearing protection,

heavy duty work gloves, sturdy work boots, and head protection.

2. IMPORTANT: This Chain Saw is equipped with an automatic Chain Brake (28) to

stop Saw Chain (77) rotation in the event of an emergency such as kickback

while in a cutting operation. (See Figure E, next page.)

3. Once the proper fuel mix is obtained, turn the Chain Saw on its side with its Fuel

Tank Cap (57) facing up. Unscrew and remove the Fuel Tank Cap. Fill the Fuel

Tank approximately 3/4 full with the fuel mix (the Fuel Tank capacity is

approxiately 18.6 ounces). Then, replace the Fuel Tank Cap. (See Figure D.)

2. To obtain the proper 25:1 fuel mix, combine 25 parts unleaded gasoline with 1

part 2-cycle oil in a clean, approved container. Cover and shake to thoroughly

mix before each fueling. NOTE: Mix only enough fuel for a few days work. The

maximum storage time of mixed fuel is

three

months.

FUEL TANK CAP (57)

FIGURE D

(77) does not come in contact with any objects on the ground. (See Figure E.)

To Start The Chain Saw:

1. WARNING! Always wear safety equipment. When operating the Chain

Saw, always wear ANSI approved safety impact eye goggles, hearing protection,

heavy duty work gloves, sturdy work boots, and head protection.

2. Check to make sure the Stop Switch (75A) is in its “STOP” position.

(See Figure E.)

3. Place the Chain Saw on a flat, level, ground surface, making sure the Saw Chain

3. The Chain Brake (28) is automatically operated by inertial force which acts on

the weight fitted inside the Brake. (See Figure E.)

4. The Chain Brake (28) can also be operated manually with the Brake turned down

towards the Guide Bar (76). (See Figure E.)

5. IMPORTANT: To avoid damaging the Clutch of the Chain Saw, immediately

release the Trigger (64) and allow the Engine to idle when the Chain Brake (28)

engages. (See Figure E.)

6. To release the Chain Brake (28), pull up on the Brake towards the Front Handle

(74) until a “click” sound is heard. (See Figure E.)

7. CAUTION! Prior to each use of the Chain Saw, make sure the Chain

Brake (28) is operating properly. To do so, turn off the Engine. Hold the Chain

Saw horizontally and tap the tip of the Guide Bar (76) against a tree stump or

piece of wood on the ground. Then check the Brake operation as discussed in

Step #6 above. (See Figure E.)

CHAIN BRAKE

(28)

STOP SWITCH

(75A)

SAW CHAIN

(77)

GUIDE BAR

(76)

FRONT HANDLE

(74)

REAR HANDLE

(22)

TRIGGER LOCKOUT BUTTON

(62)

CHOKE LEVER

(65)

STARTER HANDLE

(44)

FIGURE E

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 12

4. Set the Choke Lever (65) to the appropriate position:

A. Pull out to its “CLOSED” position if the Engine is cold. (See Figure E.)

B. Push in to its “OPEN” position if the Engine is warm. (See Figure E.)

5. Turn the Stop Switch (75A) to its “I” position. (See Figure E.)

6. Squeeze the Trigger Lockout Button (62). Then push in on the Trigger Lock (58)

to hold the Trigger (64) in its starting position. (See Figure E.)

7. Firmly press the Chain Saw to the ground, making sure the Saw Chain (77) does

not come in contact with any objects on the ground. (See Figure E.)

8. Hold the Starter Handle (44) securely, and slowly pull out the Starter Rope for a

short distance. Then, pull out the Starter Rope quickly. (See Figure E.)

9. If the Engine does not start, check again to make sure the Choke Lever (65) is in

its proper starting position and attempt to start the Engine. (See Figure E.)

10. If the Engine runs for a short while, but does not continue running, move the

Choke Lever (65) to its “OPEN” position and restart the Engine.

(See Figure E.)

12. NOTE: If the Engine is new, or has been stored for a long period of time, pull

the Starter Handle (44) several times to ensure sufficient fuel is delivered into

the fuel line and combustion chamber of the Engine. (See Figure E.)

13. WARNING! The Saw Chain (77) should never turn at idle. If necessary,

adjust the “H” and “L” Needles on the Carburetor

inward

until they stop to reduce

the idle RPM and stop the Chain. Then, set the Needles the initial number of

outward turns (“H” = 1-3/8 turns / “L” = 1-1/4 turns). Otherwise, immediately

discontinue using the Chain Saw and contact a qualified service technician to

make the adjustments.

To Stop The Chain Saw:

1. Let up on the Trigger (64). Then turn the Stop Switch (75A) to its “OFF”

position. (See Figure E.)

11. As soon as the Engine is running, check to make sure the Choke Lever (65)

is in its “OPEN” position. Squeeze the Trigger (64) briefly and let up. The

Trigger will revert to its original position, causing the Engine to idle.

(See Figure E.)

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SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 14

3. DO NOT use a back and forth sawing type motion for cutting.

4. Allow the Saw Chain (77) to cut for you. Exert only light downward pressure. If

you attempt to force the cut, damage to the Guide Bar (76), Saw Chain (77), or

Engine can result. (See Figure E.)

5. Release the Trigger (64) as soon as the cut is completed, allowing the Engine to

idle. NOTE: Running the Chain Saw at full throttle without a cutting load can

cause unnecessary wear or damage to the Guide Bar (76), Saw Chain (77), or

Engine. (See Figure E.)

6. IMPORTANT: After running the Chain Saw for an extended period of time,

allow the Engine to idle for several minutes to dissipate the heat. This will

prevent some Engine parts (ignition system, piston rings, carburetor, etc.) from

being damaged by overheating. Then turn the Stop Switch (75A) to its “OFF”

position. (See Figure E.)

To Operate The Chain Saw:

1. Maintain a proper grip on the Chain Saw whenever the Engine is running. Hold

the tool with both hands. Always keep your left hand on the Front Handle (74)

and your right hand on the Rear Handle (22), so that your body is to the left of

the chain line. Never use a left-handed (cross-handed) grip or any stance which

would place your body or arm across the chain line. (See Figure E.)

2. Accelerate the Engine to full throttle just before entering the cut by squeezing the

Trigger (64). To avoid the possiblity of kickback, keep the Engine at full throttle

the entire time you are cutting. (See Figure E.)

7. Before storing the Chain Saw, make sure to drain all fuel out of the tool’s Fuel

Tank. If this is not followed, old fuel in the Fuel Tank may clog the Carburetor

and prevent the tool from starting until cleaned out. Then store the tool in a

clean, dry, safe location out of reach of children and other unauthorized

people.

INSPECTION, MAINTENANCE, AND CLEANING

1. WARNING! Always make sure the Engine’s Stop Switch (75A) is in its

“OFF” position and the Spark Plug (11A) is removed prior to performing any

service, maintenance, or cleaning of the Chain Saw.

2. Before each use: Inspect the general condition of the Chain Saw. Check mis-

alignment or binding of moving parts, cracked or broken parts, dull or damaged

Saw Chain (77) or Guide Bar (76), and any other condition that may affect

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 15

the safe operation of the tool. If abnormal noise or vibration occurs, have the

problem corrected before further use. Do not use damaged equipment.

3. Saw Chain (77) maintenance: A dull, improperly sharpened, or damaged Saw

Chain can cause kickback, leading to possible personal injury. It is recommended

that only a qualified service technician attempt to sharpen the Saw Chain.

4. Spark Plug (11A) maintenance: The condition of the Spark Plug should be

checked every six months or 100 hours of tool use. If necessary, reset the gap

and clean the old Spark Plug or gap and replace with a new Spark Plug.

(See Figure F.)

6. To install a replacement Saw Chain (77): Refer to page 9 of this manual for

complete instructions.

7. To clean the Chain Saw: Use only a clean cloth and mild detergent. Do not

use solvents as doing so may damage the finish of the tool. Do not introduce

liquids into the internal parts of the Engine and Carburetor.

5. Air Filter (66A) maintenance: The Air Filter should be checked prior to each

use of the Chain Saw for excessive dirt and debris build-up. Thereafter, the

Air Filter should be cleaned or replaced every three months or 50 hours of tool

use.

0.025”

RECOMMENDED

SPARK PLUG TYPE:

CHAMPION® RCJ - 6Y or equivalent

FIGURE F

8. When storing the Chain Saw: Before storing, drain all fuel out of the tool’s Fuel

Tank. If this is not followed, old fuel in the Fuel Tank may clog the Carburetor

and prevent the tool from starting until cleaned out. Then store the tool in a

clean, dry, safe location out of reach of children and other unauthorized

people.

9. CAUTION! All maintenance, service, or repairs not mentioned in this

manual must only be performed by a qualified service technician.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 16

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY

DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR

DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE

OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER

AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD

BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER

ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL

PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF

REPLACEMENT PARTS THERETO.

TROUBLESHOOTING

Problem Possible Cause Possible Solution

Guide Bar and Saw Chain running hot

and smoking.

1. Chain tension too tight.

2. Chain Oil Tank empty.

1. Re-adjust Chain Tensioning Screw

to lesson tension on Chain.

2. Refill Chain Oil Tank.

Engine runs, but Saw Chain is not

rotating.

1. Chain tension too tight.

2. Damaged Guide Bar and/or Chain.

3. Worn clutch.

1. Re-adjust Chain Tensioning Screw

to lesson tension on Chain.

2. Have a qualified service technician

repair or replace Guide Bar and/or

Chain.

3. Replace clutch.

Chain rotates while Engine is at idle. 1. Engine idle speed set too high. 1. Have a qualified service technician

reset Carburetor idle adjustment

screws to lower idle (RPM) speed.

Stop Switch does not turn off Engine. 1. Defective Stop Switch. 1. Immediately remove Spark Plug

Cap from Spark Plug to stop Engine.

Discontinue using Chain Saw until a

qualified service technician can repair

or replace Stop Switch.

PARTS LIST - CHAIN SAW UNIT

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 17

Part # Description Qty. Part # Description Qty.

1 Right Cover Assy. 1 40 Washer (5) 1

2 Shield Pin 1 41 Starter Plate 1

3 Shield Pin Spacer 1 42 Coil Spring 1

4 Ring (3) 1 43 Starter Coil Spring 1

5 Spacer Pin 1 44 Starter Handle 1

6 Secondary Brake Spring 1 45 Starter Rope 1

7 Brake Spring 1 46 LH Sheathing 1

8 Brake Control Rod 1 47 Starter Cover 1

9 Secondary Pull Rod 1 48 Fuel Tube 1

10 Pin (3 x 9) 1 49 Fuel Filter 1

11 Main Level 1 50 Rubber 1

12 Tensioning Screw 1 51 Base 1

13 Tension Block 1 52 Oil Tank Cap 1

14 Tapping Screw (ST4 x 8) 5 53 Tapping Screw (ST5 x 16) 4

15 Brake Spring Cover Plate 1 54 Dust Cover 2

16 Rubber Washer 1 55 Anti-Drop Plate 1

17 Shield Ring (5) 1 56 Packing Washer (20 x 30 x 2) 1

18 Washer (6) 1 57 Fuel Tank Cap 1

19 Brake Torsion Rod Spring 1 58 Trigger Lock 1

20 Tensioning Cover Plate 1 59 Button Spring 1

21 Chain Guide 1 60 Pin (6 x 30) 1

22 Rear Handle 1 61 Tapping Screw (ST4 x 25) 1

23 Brake Strap 1 62 Trigger Lockout Button 1

24 Dust Shield 1 63 Trigger Torsion Rod Spring 1

25 Shield Ring (4) 1 64 Trigger 1

26 Spacing Shield 1 65 Choke Lever 1

27 Rubber Cushion 1 66 Shaft 2

28 Chain Brake 1 67 Handle Cover 1

29 Tension Gear 1 68 Balancer Oil Tube 1

30 Nut (M8) 2 69 Balancer Body 1

31 Air Filter Lock Nut 1 70 Balancer Rubber 1

32 Lock Nut Washer (15 x 26 x1) 1 71 Balancer Cover 1

33 Air Filter Cover 1 72 Sealing Rubber 1

34 Idle Adjusting Guide 1 73 Tapping Screw (ST4 x 13) 1

35 Screw (M5 x 16) 11 74 Front Handle Assy. 1

36 Upper Cover Plate 1 74 Front Handle Assy. 1

37 Starter Assy. 1 75 Plug Wrench 1

38 Shroud 1 76 Guide Bar 1

39 Screw (M5 x 10) 1 77 Saw Chain 1

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 18

ASSEMBLY DIAGRAM - CHAIN SAW UNIT

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Plug Wrench (75) not shown.

Guide Bar (76) not shown.

Saw Chain (77) not shown.

PARTS LIST - ENGINE

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 19

Part # Description Qty. Part # Description Qty.

1A Cylinder Body 1 51A Turbine 1

2A Nut (M5) 2 52A Cover Plate 1

3A Washer (5) 15 53A Oil Seal (15 x 28 x 4.5) 1

4A Washer (5) 2 54A Bearing (6202 Grade D 15 x 35 x 11) 1

5A Silencer Cover Plate 1 55A Shock Block (1) 1

6A Silencer Body 1 56A Throttle Lever Retaining Bracket 1

7A Silencer Sealing Plate 1 57A Throttle Rod 1

8A Muffler Connecting Screw 2 58A Right Shock Block 1

9A Screw (M5 x 20) 6 59A Cushion Socket 3

10A Washer (5) 11 60A Air Intake Support 1

11A Spark Plug (NHSP LD L8RTF) 1 61A Backing Plate 1

12A Air Intake Tube Sealing Plate 1 62A Air Intake Support Sealing Plate 1

13A Air Intake Tube 1 63A Air Intake Flange 1

14A Screw (M5 x 12) 4 64A Carburetor 1

15A Hold Coil 1 65A Air Intake Socket 1

16A Cylinder Sealing Plate 1 66A Air Filter 1

17A Piston Ring 2 67A Double Screw Bolt (GM5-M5 x 30) 1

18A Piston 1 68A Air Intake Socket Cushion 1

19A Piston Pin Circlip 2 69A Nut (M5 x 50) 2

20A Piston Pin 1 70A Right Case Body 1

21A Needle Bearing Ring 2 71A Dust Plate 1

22A Crankshaft Connecting Bar 1 72A Pin (5 x 10) 3

23A Needle Bearing (11 x 15 x 12.5) 1 73A Shoe Block (2) 1

24A Semi-Circular Key (3 x 3.5 x 10) 1 74A Ground Strip 1

25A Conical Spreader Spring 1 75A Stop Switch 1

26A Conical Spreader Base 1 76A Stop Switch Socket 1

27A Tapping Screw (ST5 x 16) 4 77A Left Shock Block 1

28A Chain Catcher 1 78A Screw (M5 x 25) 5

29A Screw (M5 x 16) 1 79A Oil Seal Damper 1

30A Aeration Jet 1 80A Washer (4) 2

31A Aeration Jet Circlip 1 81A Washer (4) 2

32A Sponge Transition Block 1 82A Screw (M4 x 10) 6

33A Bumper Spikes 1 83A Flywheel 1

34A Screw (M5 x 10) 5 84A Washer (8) 1

35A Oil Filter Screen 1 85A Nut (M8 x 1) 1

36A Oil Filter 1 86A Packing Washer (20 x 30 x 2) 1

37A Oil Tube 1 87A Anti-Drop Plate 1

38A Screw (M4 x 14) 2 88A Oil Cover 1

39A Oil Pump 1 89A Suction Tube Circlip 2

40A Sponge Transition Coil 1 90A Suction Tube (2.5 x 7 x 105) 1

41A Nozzle 1 91A Suction Jet 1

42A Chain Guide Block 1 92A Left Case Body 1

43A Double Screw Bolt (AYM8-M8 X 26 – 8.8) 2 93A Ring (35) 1

44A Shoe Block 3 94A Oil Seal (15 x 35 x 4.5) 1

45A Retainer 1 95A Ignition 1

46A Clutch Extension Spring 1 96A Conductor 1

47A Clutch Adjusting Washer 1 97A Dust Cover 3

48A Needle Bearing (12 x 15 x 14.5) 1 98A Case Body Sealing Plate 1

49A Clutch Shell 1 99A Damper 1

50A Sprocket 1

ASSEMBLY DIAGRAM - ENGINE

SKU 95497 For technical questions, please call 1-800-444-3353 PAGE 20

35A

10A

11A

12A

13A

14A 15A

16A

17A

18A

22A

24A

29A

28A

27A

26A

25A

35A

36A

37A

41A

38A

39A

40A

34A

33A

32A

31A

30A

82A

99A

42A

43A

55A

54A

53A

52A

82A

51A

50A

49A

48A

47A

45A

44A46A

19A

20A

21A

23A

56A

57A

58A 59A

61A

60A 14A 62A

63A

64A 65A

69A

68A

67A

66A

70A

71A

72A

98A

89A

90A

89A

91A

95A

96A

73A

76A75A74A

77A

92A

93A

94A

97A

78A

79A

81A

83A

85A

84A

82A

80A

88A

86A

87A

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

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CHICAGO 95497 Assembly And Operating Instructions Manual

Brand: CHICAGO

Model: 95497

Category: Power chainsaws

Type: Assembly And Operating Instructions Manual

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CHICAGO 95497 Assembly And Operating Instructions Manual

CHICAGO 95497 Assembly And Operating Instructions Manual

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