Hitachi CS51EAP User manual
- Category
- Power chainsaws
- Type
- User manual
This manual is also suitable for
PRODUCT NAME
Hitachi Engine Chain Saw
Models CS 51EAP
CS 51EA
International Sales Division
䌃
TROUBLESHOOTING GUIDE ---------------------------------------------------------------------------------------------- 1
1. Troubleshooting and correction ------------------------------------------------------------------------------- 1
REPAIR GUIDE ----------------------------------------------------------------------------------------------------------------- 3
1. Precaution on maintenance, inspection and repair ------------------------------------------------------ 3
2. Inspection criteria for each section and consumable parts -------------------------------------------- 3
CONTENTS
Page
LIST Nos.
CS 51EAP: F009
CS 51EA: F008
Feb. 2012
-1-
1. Troubleshooting and correction
Trouble Cause Corrective action
Starter
handle
cannot be
pulled.
The crank shaft does
not rotate.
Faulty piston ring
Disassembly and parts
replacement
Seized piston and cylinder
Faulty crank shaft bearings
Magneto rotor contact with
ignition coil
The recoil starter does
not rotate.
Broken recoil starter
Inspection and replacement
Faulty starter pawl
Startup is
impossible.
No compression
Faulty piston ring
Parts replacement
Worn piston
Expired oil seal service life
Worn cylinder
Defective sealing of the packing
Faulty decompression valve Cleaning or replacement
Short-circuited due to foreign matter between the spark plug
electrodes.
Removal of foreign matter: In
case of frequent occurrence,
disassemble and clean the
engine.
No spark
Stop switch not at startup position Adjust to startup position.
Dirty or faulty spark plug
Cleaning or replacement
Improperly connected plug cap Inspection and replacement
Disconnected or improperly
connected high voltage cord
Repair or replacement
Ground connection of high
voltage cord
Repair
Disconnected or faulty ignition
coil ass’y
Replacement
Large gap between the magneto
rotor circumference and ignition
coil ass’y
Adjustment
The spark plug does
not become wet with
fuel after repeated
starting operation.
No fuel in the fuel tank
Add properly mixed fuel
(25:1 to 50:1).
Clogged fuel filter Cleaning or replacement
Faulty fuel pipe
Adjustment, replacement or
connection
Faulty vent hole (inner cap) on
the fuel tank
Replacement
Faulty carburetor ass’y
Adjustment, cleaning or
replacement
The spark plug is wet
due to excessive fuel
supplied.
Starter handle pulled repeatedly
with choke button pulled out (set
at “startup”)
Dry the spark plug.
Remove excessive fuel.
Idling stops
although
startup is
possible.
Weak spark
Dirty or faulty spark plug Cleaning or replacement
Improper air gap Adjustment
Low compression
Worn piston ring
Replacement
Expired oil seal service life
Faulty decompression valve Cleaning or replacement
Good spark and
compression
Revolutions too low for idling
Adjustment
Poorly adjusted carburetor ass’y
TROUBLESHOOTING GUIDE
-2-
Trouble Cause Corrective action
Starts, but
when
accelerating
…
The engine stalls.
Clogged fuel filter Cleaning or replacement
Insufficient warm-up Warm-up
Poorly adjusted carburetor ass’y Adjustment
Poor acceleration; no
increase in revolutions
Clogged cylinder vent passage,
exhaust port and/or
carbon-clogged muffler
Cleaning
Clogged air cleaner
Chain brake set on Release
Poorly adjusted carburetor ass’y
Adjustment, cleaning or
replacement
Starts, but
…
Fluctuating revolutions
at high speed
Dirt-clogged high-speed fuel line Cleaning
Defective sealing of the packing Replacement
Faulty carburetor ass’y
Adjustment, cleaning or
replacement
Excessive fuel
consumption
Clogged air cleaner Cleaning
Poorly adjusted carburetor ass’y Adjustment
Chain oil is not discharged.
Insufficient amount of chain oil in
the oil tank
Insufficient chain oil in the oil
tank
Clogged chain oil discharge port
Cleaning
Clogged oil filler port on the guide
bar
Clogged oil filter
Poor adjustment of chain oil
discharge amount
Poorly adjusted chain oil
discharge amount
Faulty oil pump Faulty oil pump
-3-
This section describes repair, focusing on portions requiring frequent repair. See TROUBLESHOOTING
GUIDE in the previous section as the context for the following descriptions.
1. Precautions on maintenance, inspection and repair
• The fuel used readily ignites; therefore, never bring the product near a flame.
• Use new gaskets at reassembly.
• Prior to disassembly for repair, remove the fuel and chain oil into separate containers, and allow the engine
to cool down.
• During repair, startup or running, use adequate care for portions posing the risk of burn injury or electric
shock, such as hot areas including the muffler, high voltage cord, and spark plug.
• Before running the product with the guide bar and saw chain attached, make sure that there are no other
people nearby.
• Ensure proper ventilation when performing repair in a small room or other poorly ventilated space.
2. Inspection criteria for each section and consumable parts
Model
Item
CS 51EAP CS 51EA
Idling revolutions 3,000 ± 200 min
-1
(rev./min.)
No-load maximum revolutions
(with guide bar and saw chain)
13,500 min
-1
(rev./min.)
Clutch engagement 3,900 to 4,600 min
-1
(rev./min.)
Accelerating performance Smooth acceleration
Gap between magneto rotor and
ignition coil ass’y
0.2 to 0.4 mm
Spark plug NGK BPM7A or NGK BPMR7A
Gap between spark plug electrodes 0.6 to 0.7 mm
Saw chain type OREGON 95VPX, 20BPX
Saw chain pitch x gauge 8.26 mm (0.325 in.) x 1.27 mm (0.05 in.)
No. of saw chain drive links 56, 64, 66, 72, 78
REPAIR GUIDE
-4-
Seized or broken piston ring Replacement
Seized piston or cylinder Replacement
Seized or broken needle bearing of the crank
shaft
Replacement
Seized ball bearing Replacement
Magneto rotor contact with ignition coil Adjustment
Broken recoil starter Inspection/replacement
Faulty starter pawl Inspection/replacement
Faulty piston ring Cleaning/replacement
Worn piston ring Replacement
Worn piston Replacement
Worn or damaged oil seal Replacement
Worn cylinder Replacement
Defective sealing of the packing Replacement
Defective decompression valve Replacement
Remove foreign matter. Disassembly/cleaning
Stop switch not at startup position
Setting to startup
position
Dirty or faulty spark plug Cleaning/inspection
Improperly connected plug cap Inspection/replacement
Disconnected or improperly connected high
voltage cord and other wiring
Inspection/replacement
Ground connection of high voltage cord and
other wiring
Inspection
Disconnected or faulty ignition coil
Replacement
Excessive gap between magneto rotor
circumference and ignition coil
Adjustment
No fuel in fuel tank or improper mixing ratio
Add properly mixed fuel
(25:1 to 50:1).
Clogged fuel filter Cleaning/replacement
Bent fuel pipe Adjustment
Cracked fuel pipe Replacement
Fallen fuel pipe Connection
Faulty tank vent hole (inner cap) Replacement
Faulty pump diaphragm of carburetor ass’y Replacement
Dirt-clogged carburetor ass’y Cleaning
Poorly adjusted carburetor ass’y Adjustment
Starter handle pulled repeatedly with choke
button pulled out (set at “startup”)
Dry the spark plug.
Remove excessive fuel.
Re
p
air flowchart
Pull the starter handle.
Is pulling possible?
Remove the spark plug to
check for sparks.
Sparks are generated.
Dry
There is compression.
Return the spark plug
and plug cap to the
original positions, and
then perform proper
startup operation.
Confirm that the tip of the
spark plug becomes wet
with fuel.
Wet spark plug due to
excessive supply of fuel
OK
Is the spark plug
contaminated with foreign
matter?
Contaminated
No spark
Impossible to pull
OK
No compression
OK
Wet
OK
OK
OK
-5-
Dirty or faulty spark plug Cleaning/replacement
Defective air gap
Adjustment
Worn piston ring
Replacement
Expired oil seal service life
Replacement
Defective decompression valve
Cleaning/replacement
Revolutions too low for idling Adjustment
Poorly adjusted carburetor ass’y Adjustment
Revolutions too low for idling Adjustment
Poorly adjusted carburetor ass’y Adjustment
Defective sealing of the packing Replacement
Revolutions too high for idling Adjustment
Worn or faulty clutch Inspection/replacement
Poorly adjusted carburetor ass’y Adjustment
Clogged fuel filter
Cleaning/replacement
Inadequate warm-up, especially in cold
weather
Warm-up
Poorly adjusted carburetor ass’y
Adjustment
Clogged cylinder vent passage, exhaust port
or carbon-clogged muffler
Cleaning
Clogged air cleaner
Cleaning
Chain brake set on
Release
Poorly adjusted carburetor ass’y
Adjustment
Faulty carburetor ass’y pump diaphragm
Replacement
Dirt-clogged carburetor ass’y
Cleaning
Dirt-clogged high-speed fuel line of the
carburetor ass’y
Cleaning
Air intake from the packing section Inspection
Faulty carburetor ass’y pump diaphragm Replacement
Poorly adjusted carburetor ass’y Adjustment
Revolutions too low for idling Adjustment
Poorly adjusted carburetor ass’y Adjustment
Clogged air cleaner Cleaning
Poorly adjusted carburetor ass’y Adjustment
Insufficient chain oil in the oil tank Supply oil.
Clogged chain oil discharge port Cleaning
Clogged guide bar oil feed port Cleaning
Clogged oil filter Cleaning
Poorly adjusted chain oil discharge amount Adjustment
Defective oil pump Replacement
When the speed rapidly
decelerates from high speed…
Revolutions fluctuate
The engine stalls
OK
OK
The engine stalls
The engine starts, but when
the throttle lever is pulled…
OK
High speed unavailable
Pulling the throttle lever
increases the speed.
When the revolutions
increase…
When the product is tilted
during idling…
The engine stalls
OK
The saw chain starts
rotating during idling.
Starts rotating
The engine stalls
OK
Starts up, and when idling
mode is set…
Is fuel consumption excessive?
Excessive
OK
Is chain oil discharged?
OK
No discharge
OK
-6-
Ɣ Spark plug
High voltage cord
Ignited sparks
Spark Plug [46]
Plug cap
Ɣ Checking for sparks
Metallic portion of the engine
[Bold] numbers in the descriptions below correspond to item numbers in the Parts List and exploded
assembly diagram for the Models CS 51EAP and CS 51EA.
Always stop the engine prior to disassembly or when replacing the saw chain.
1. Checking the spark of the spark plug
CAUTION:
Ɣ Be careful not to touch the metallic portion of the Spark Plug
[46] when pulling the starter handle; otherwise, you run the
risk of electric shock.
Ɣ Carefully wipe off any fuel around the plug to avoid a
sudden flash of fire.
(1) Remove the Spark Plug [46] from the Cylinder [73].
Use a wire brush to clean off carbon deposits on the Spark
Plug [46] electrodes, as needed. Adjust the gap between the
electrodes if necessary. Use a cloth to wipe off any fuel on
the electrodes. Remove fuel left in the Engine Case (A)
Ass’y [87] and Engine Case (B) Ass’y [80] by following the
procedure below.
(a) With the Spark Plug [46] removed from the Cylinder [73]:
(b) Open the Choke Button [93] (by pushing it in), and then
set the Stop Switch [95] to the stop position.
(c) Open the throttle (by pulling the Throttle Lever [149]).
(d) Pull the starter handle several times.
(2) Insert the Spark Plug [46] into the Plug Cap [162], and then
place the electrodes in contact with the metallic portion of
the engine. Under these conditions, set the Stop Switch [95]
to the startup position and pull the starter handle.
(3) When all the above are normal, the Spark Plug [46]
electrodes make a snapping sound to generate sparks.
2. Adjustment of the carburetor
(1) Use the Idle Adjust Screw [63] to adjust the carburetor.
Ɣ Idle Adjust Screw [63]
Use this screw to adjust revolutions at idling. Turning the
screw clockwise increases engine revolutions; turning it
counterclockwise decreases engine revolutions.
(2) Standard setting of the carburetor
Ɣ 3,000 ± 200 min
-1
(rev./min)
(3) Fine adjustment
Ɣ Idling adjustment
(a) Use the Idle Adjust Screw [63] to set revolutions so that
the Saw Chain [115] does not start rotating while the
engine runs stably.
(b) Set idling revolutions to 2,800 to 3,200 min
-1
(rev./min) by using the Idle Adjust Screw [63].
(Adjust to approx. 3,000 min
-1
(rev./min).)
Adjust the idling revolutions after the engine is fully warmed up.
(Tip on warm-up: Let the engine idle for one minute with the engine in half-throttled status.)
Inspection and repair procedures
Ɣ Idle adjust screw
Idle Adjust Screw [63]
Revolutions
decrease.
Revolutions
increase.
Gap between
electrodes
(0.6 to 0.7 mm)
Remove carbon here.
-7-
Cleaner Knob [6]
Knob Packing [7]
Cleaner Cover [2]
Cleaner Element (B) [8]
Cleaner Element (A) [9]
Cover Set Bolt [4]
Carburetor Insulator (C51) [50]
Carburetor Ass’y [52]
Cleaner Support [71]
Hex. Socket Hd. Bolt
M5 x 12 (Precote) [38]
Cylinder Cover [5]
Clip [31]
Fuel Pipe [68]
Hex. Socket Hd. Bolt M5 x 45 [70]
Operation Plate [94]
Choke Rod Rubber [92]
Choke Button [93]
Fuel Pipe (FKM) [51]
Fuel Pipe [72]
Shutter Plate [3]
Washer 5 [69]
Washer 5 [69]
Ɣ Cleaner and carburetor
1. Disassembly and reassembly of the cleaner and carburetor
[Tools required]
Ɣ Phillips screwdriver
Ɣ Hex. bar wrench (4mm)
(1) Disassembly
Ɣ Loosen the Cleaner Knob [6] and remove the Cleaner Cover [2].
Ɣ
Use a Phillips screwdriver to loosen the three Cover Set Bolts
[4]
, and then remove the Cylinder Cover
[5]
.
Ɣ Pull out Cleaner Element (A) [9] and Cleaner Element (B) [8].
Ɣ Remove the Clip [31] and pull out the Fuel Pipes [68] [51] [72] from the Carburetor Ass’y [52]. Use a
hex. bar wrench (4 mm) to remove the Hex. Socket Hd. Bolt M5 x 12 (Precote) [38] and two Hex.
Socket Hd. Bolts M5 x 45 [70]. Then remove the Cleaner Support [71] and Carburetor Ass’y [52].
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Do not bend the Fuel Pipes [68][51][72]. (See “2. Connecting the fuel pipes” for details.)
Ɣ Apply 0.1 to 0.2 gram of Alvania Grease RL3 to the sliding portion of the Choke Rod Rubber [92] for
the Choke Button [93]. Pull out the Choke Button [93] and then turn the throttle of the carburetor.
Make sure that the Choke Button [93] returns automatically and the carburetor’s choke valve opens to
its initial position.
Ɣ Apply 0.1 to 0.2 gram of Alvania Grease RL3 to the lug portions (to be fitted in the grooves of the
Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80])) of the Operation Plate [94].
Ɣ Be careful not to get Cord (A) [163] and Cord (B) [164] caught in the Cylinder Cover [5].
Disassembly and reassembly
-8-
2. Connecting the fuel pipes
Make the connections as shown in the illustration below.
(1) Fully insert the pipes down to their roots.
(2) Do not bend or twist the pipes.
(3) Be careful not to get pipes in the respective portions caught in other parts.
(4) The end faces of the Fuel Pipe 2.5 x 4 x 90 [43] and Fuel Pipe [68] should protrude from the edge of the
Fuel Grommet [152] by 55 to 60 mm and 167 to 172 mm, respectively.
CAUTION: Never mix up fuel pipes inserted into the Priming Pump Comp. [44].
Ɣ Fuel pipe connection chart
Priming Pump Comp. [44]
Fuel Pipe [72]
Carburetor Ass’y [52]
Fuel Pipe 2.5 x 4 x 90 [43]
Fuel Pipe [68]
Cleaner Support [71]
Clip [31]
Fuel Pipe (FKM) [51]
Clip [31]
Fuel Grommet (A) [41]
Grommet [42]
7 mm or more
Color: Black
Color:
Transparent
CAUTION: Check the positional
relation of the Fuel
Pipes [68] and [72].
7 mm or more
Fuel Pipe 2.5 x 4 x 90 [43]
Fuel Pipe [68]
Fuel Grommet [152]
-9-
ၥၷှျၱၑၥ[162]
Ɣ Recoil starter
Air Deflector [175]
Recoil Starter [176]
Cover Set Bolt [4]
Air Deflector [175]
Cord (A) [163]
Cord (B) [164]
High voltage cord
CAUTION: Place Cord (A) [163] and Cord (B)
[164] into the groove of the Air
Deflector [175] for assembly.
CAUTION: Move the excess cords
here to take up the
slack of Cord (A) [163]
and Cord (B) [164].
3. Disassembly and reassembly of the recoil starter
[Tool required]
Ɣ Phillips screwdriver
(1) Disassembly
Ɣ Pull out the Plug Cap [162] from the Spark Plug [46].
Ɣ Use a Phillips screwdriver to loosen the four Cover Set Bolts [4], and then remove the Recoil Starter
[176] and Air Deflector [175].
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Place Cord (A) [163] and Cord (B) [164] into the groove of the Air Deflector [175] for assembly.
Ɣ Place the high voltage cord of the ignition coil into the groove of the Air Deflector [175] for assembly.
Ɣ Apply 0.05 to 0.1 g of Chemiseal L-391 (manufactured by Chemitech Inc.) on the female threads of the
Cover Set Bolt [4] before mounting the Recoil Starter [176].
Ɣ Assembling the Recoil Starter [176] is made easier by first pulling the starter handle, and then
returning it a little.
-10-
Damper [124]
Damper Set Bolt [15]
Nut M6 [10]
Rear handle ass’y
Spring Holder [155]
Antivibration Spring [157]
Engine case ass’y
Fuel Pipe [68]
Rear Damper [88]
Ɣ Rear handle and engine case
4. Disassembly and reassembly of the rear handle and engine case
[Tools required]
Ɣ Flat-blade screwdriver
Ɣ Box end wrench 10 x 19 mm
(1) Disassembly
Ɣ Remove the Fuel Pipe 2.5 x 4 x 90 [43] from the
Priming Pump Comp. [44].
Ɣ Secure the Spring Holders [155] [12] by inserting a
flat-blade screwdriver into the groove of the bolt,
and then use a box end wrench 10 x 19 mm to
remove Nut M6 [10].
Ɣ Remove the Damper [124], and then use a
flat-blade screwdriver to remove the two Damper
Set Bolts [15]. Also remove the Rear Handle [146].
(2) Reassembly
Reassembly can be conducted by reversing the
disassembly procedure. However, special attention
should be given to the following items.
Ɣ Insert the Antivibration Springs [157] [14] so that their first coils do
not protrude from the first coils of the Spring Holders [155] [12].
(See the illustration above.)
Ɣ Apply 0.1 to 0.3 g of Chemiseal L-391 (manufactured by Chemitech
Inc.) to the bolts of the Spring Holders [155] [12] or on the female
threads of Nut M6 [10].
Ɣ Secure the Spring Holders [155] [12] by inserting a flat-blade
screwdriver into the groove of the bolt as illustrated on the right,
and then tighten Nut M6 [10] so that the Spring Holders [155] [12]
do not rotate when you turn the screwdriver by using a box end
wrench 10 x 19 mm.
Ɣ Use the box end wrench 10 x 19 mm to hold Nut M6 [10] in place, and then use a torque wrench with a
flat bit to tighten the bolts of the Spring Holders [155] [12] at the specified torque of 5.5 ± 0.5 N•m (56 ±
5 kgf•cm).
CAUTION: Do not twist the Fuel Pipe [68] between the rear handle and engine case.
Ɣ Tightening Nut M6 [10]
Nut M6 [10]
Ɣ Assembling the antivibration structure of coil spring
1 mm or less
The Antivibration Springs [157] [14] should not protrude
from this surface of the Spring Holders [155] [12].
Rear Handle [146]
Flanged Tapping
Screw D6 [156]
A
ntivibration
Springs [157] [14]
Spring Holders [155] [12]
-11-
Clutch [131]
Clutch Washer (B) [132]
Clutch Housing [133]
Needle Bearing [134]
Rim Sprocket [135]
Clutch Washer [136]
Seal Lock Screws M4 x 10 [16]
Oil Pump Cover [137]
Worm [138]
Oil Pump [30]
Oil Pipe [29]
Clip [31]
Machine Screw M4 x 16 [28]
Air Vent Valve (B) [140]
Ɣ Clutch and oil pump
Air Vent Sponge [139]
5. Disassembly and reassembly of the clutch and oil pump
[Tools required]
Ɣ J-361 jig (No.6698723) (clutch puller)
Ɣ Phillips screwdriver
(1) Disassembly
Ɣ Align the pawl of the J-361 jig (clutch puller) with the Clutch [131],
and then use an impact driver to turn it in the arrow direction as
shown in the illustration on the right to remove the Clutch [131].
Remove Clutch Washer (B) [132], the Clutch Housing [133], Needle
Bearing [134], Rim Sprocket [135], and Clutch Washer [136].
CAUTION: Note that the Clutch [131] is screwed into the Crank
Shaft [83] with left-hand threads. Do not remove Spark
Plug BPM-7A/BPMR7A [46] from the Cylinder [73]. Turn
off the Decomp. [45] (by pulling it toward you).
Ɣ Remove the three Seal Lock Screws M4 x 10 and [16] Oil Pump Cover [137].
CAUTION: The threads of the Seal Lock Screws M4 x 10 [16] may be easily broken. Therefore,
do not tighten the screws too much.
Ɣ Remove the Machine Screw M4 x 16 [28] and Clip [31], and then remove the Oil Pipe [29] from the Oil
Pump [30]. Finally, remove the Oil Pump [30] from the main body.
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Before mounting the Worm [138], apply 0.1 to 0.3 gram of Alvania Grease RL3 to its inner diameter.
Ɣ Before mounting the Oil Pump
[30]
, apply 0.6 to 1.0 gram of Alvania RL3 on the gear portion of the Worm
[138]
.
Ɣ Securely engage the Oil Pump [30] with the gears of the Worm [138].
Ɣ Place the Clutch Washer [136] on the protrusions of the Worm [138] for assembly. (See the illustration
titled “Mounting the clutch washer” on the next page for details.)
Ɣ Before mounting the Clutch [131], degrease the female threads of the Clutch [131] and the threads of
the Crank Shaft [83].
Ɣ Use the Hitachi 14.4V impact driver to tighten the Clutch [131] for about one second, in order to obtain
the specified torque.
CAUTION: Ɣ Never tighten excessively. Otherwise, the flange of the Worm [138] may break and
thus inhibit removal.
Ɣ Run the assembled chain saw and make sure the Clutch [131] is firmly tightened.
Ɣ Removing the clutch
J-361 jig (clutch puller)
Clutch [131]
-12-
Ɣ Mounting the clutch washer
Clutch Washer [136]
Worm [138]
Rim Sprocket [135]
Needle Bearing [134]
Clutch Housing [133]
Clutch [131]
Clutch Washer (B) [132]
Crank Shaft [83]
Clutch Washer [136]
Worm [138]
Place the Clutch Washer [136] on the protrusion
of the Worm [138] before assembly.
Protrusions
6. Disassembly and reassembly of the magneto rotor
[Tools required]
Ɣ J-363 jig (No.6694822) (8 x 120 handle)
Ɣ J-357 (No.6695737) (center bolt)
Ɣ J-356 jig (No.6695736) (complete rotor extraction tool)
Ɣ J-365 jig (No.6695739) (stepped bolt 5 mm)
Ɣ Socket wrenches (10 mm and 13 mm)
Ɣ M8 nut
(1) Disassembly
Ɣ Use a 10-mm socket wrench to remove the two Step Bolts [174]. Then remove the two Shims [173],
two Starter Pawls [172], two Starter Pawl Springs [170], and two Washers 0.8 [171].
Ɣ Use a 13-mm socket wrench to remove Flange Nut M8 [112].
Ɣ With the screw end face of the Crank Shaft [83] made
flush with the upper face of a commercially available
M8 nut, rotate the J-363 jig (8 x 120 handle) in the
arrow direction and tighten the J-357 jig (center bolt)
as shown in the illustration on the right. Then remove
the Magneto Rotor [169].
(2) Reassembly
Reassembly can be conducted by reversing the
disassembly procedure. However, special attention
should be given to the following items.
Ɣ Before mounting the Magneto Rotor [169], degrease
the tapered section of the Magneto Rotor [169], as
well as the threads and tapered section of the Crank
Shaft [83].
Ɣ When removing the Magneto Rotor [169] or Ignition
Coil [166], adjust the clearance between the Magneto
Rotor [169] and Ignition Coil [166] as per “7.
Adjustment of clearance between the magneto rotor
and ignition coil.”
Ɣ After reassembly, check the operation of the Starter Pawl [172].
J-363 jig (8 x 120 handle)
J-357 (center bolt)
Magneto Rotor [169]
J-356 jig
(complete rotor
extraction tool
)
J-365 jig
(stepped bolt 5 mm)
Ɣ Removing the magneto rotor
-13-
Ɣ Magneto rotor
Magneto Rotor [169]
Starter Pawl Spring [170]
Washer 0.8 [171]
Starter Pawl [172]
Shim [173]
Step Bolt [174]
Flange Nut M8 [112]
Crank Shaft [83]
7. Adjustment of clearance between the magneto rotor and ignition coil
(1) Loosen the Hex. Socket Hd. Bolt (W/Flange)
M4 x 18 [167] so as to temporarily secure
the Ignition Coil [166].
(2) Insert a 0.3-mm thickness gauge between
the Ignition Coil [166] and the perimeter of
the Magneto Rotor [169].
(3) Under this condition, firmly tighten the Hex.
Socket Hd. Bolt (W/Flange) M4 x 18 [167].
Ɣ Adjustment of clearance between the magneto rotor and
ignition coil
Magneto Rotor [169]
0.2 to 0.4 mm
0.2 to 0.4 mm
Hex. Socket Hd. Bolt
(W/Flange) M4 x 18 [167]
Ignition Coil [166]
-14-
• Wiring diagram
Spark Plug BPM-7A/BPMR7A [46]
Cord (A)[163]
Ignition Coil [166]
Cord (B) [164]
Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [167]
Plug Cap [162]
Cable Tie [161]
Stop Switch [95]
Operation Plate [94]
Connecto
r
(Silve
r
)
Connecto
r
(Brass color)
• Cable tie securing position
Cord (B) [164]
Cord (A)[163]
Cut off the surplus end of the Cable Tie [161] with
2 to 5 mm of strap projecting from its locking head.
Cable Tie [161]
Concave portion of Cord (A) [163] and Cord (B) [164]
Cord (B) [164]
Cord (A)[163]
Cable Tie [161]
8. Wiring diagram
The following diagram shows the wiring.
(1) Connect the connector (silver) of Cord (A) [163] to the Ignition Coil [166].
(2) Fix Cord (B) [164] to the Ignition Coil [166] with the Hex. Socket Hd. Bolt (W/Flange) M4 x 18 [167].
(3) Fit the Stop Switch [95] into the Operation Plate [94] so that indication “1” faces up.
(4) Connect the connectors (brass color) of Cord (A) [163] and Cord (B) [164] to the connectors of the Stop
Switch [95].
(5) Bundle together Cord (A) [163] and Cord (B) [164], and then secure the concave portion of the bundle
with the Cable Tie [161].
CAUTION: Do not get Cord (A) [163] and Cord (B) [164] caught in other parts.
-15-
• Muffler
Muffler Packing [40]
Muffler [39]
Hex. Socket Hd. Bolt M5 x 12 (Precote) [38]
Seal Lock Hex. Socket Hd. Bolt M6 x 20 [37]
Muffler Cap [36]
Muffler Protector [26]
Muffler Protector Gauze [27]
Muffler Gauze [20]
Exhaust Pipe [19]
Hex. Socket Hd. Bolts
M4 x 10 [24]
Bolt Washers M4 [25]
9. Disassembly and reassembly of the muffler
[Tools required]
Ɣ Hex. bar wrenches (3 mm, 4 mm and 5 mm)
Ɣ Flat-blade screwdriver
(1) Disassembly
Ɣ Use a flat-blade screwdriver to remove the two Muffler Caps [36]. Use a 5-mm hex. bar wrench to
remove the two Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]. Use a 4-mm hex. bar wrench to remove
the two Hex. Socket Hd. Bolts M5 x 12 (Precote) [38]. Then remove the Muffler [39].
Ɣ Use a 3-mm hex. bar wrench to remove the five Hex. Socket Hd. Bolts M4 x 10 [24] and five Bolt
Washers M4 [25]. Then remove the Muffler Protector [26], Muffler Protector Gauze [27], Exhaust Pipe
[19], and Muffler Gauze [20].
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Do not reuse the Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37], Hex. Socket Hd. Bolts M5 x 12
(Precote) [38], and Muffler Caps [36].
Ɣ Before mounting the Muffler [39], degrease the screw holes of the Cylinder [73], Engine Case (A) Ass’y
[87], and Engine Case (B) Ass’y [80].
Ɣ Mount the Muffler [39] by temporarily securing the two Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]
and the two Hex. Socket Hd. Bolts M5 x 12 (Precote) [38], and then firmly tighten all four bolts.
-16-
10. Disassembly and reassembly of the cylinder and scavenging cover
[Tools required]
Ɣ Hex. bar wrenches (4 mm and 5 mm)
Ɣ Phillips screwdriver
Ɣ Socket wrenches (13 mm and 19 mm)
(1) Disassembly
Ɣ Use a 19-mm socket wrench to remove Spark Plug BPM-7A/BPMR7A [46].
Ɣ Use a 5-mm hex. bar wrench to remove the four Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]. Then
remove the Cylinder [73].
Ɣ Use a Phillips screwdriver to remove the eight Seal Lock Screws M4 x 10 [16]. Then remove
Scavenging Cover (A) [74] and Scavenging Cover (B) [17].
CAUTION: The threads of the Seal Lock Screws M4 x 10 [16] may be easily broken. Therefore,
do not tighten the screws too much.
Ɣ Use a 13-mm socket wrench to remove the Decomp. [45].
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Do not reuse the Cylinder Packing (C51) [75], Cover Packing [18], and Intake Packing (C51) [47].
Ɣ Do not reuse the Seal Lock Screws M4 x 10 [16], Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37], and
Hex. Socket Hd. Bolts M5 x 12 (Precote) [38].
Ɣ Before mounting the Cylinder [73], degrease the screw holes of the Engine Case (A) Ass’y [87] and
Engine Case (B) Ass’y [80].
Ɣ Before mounting Scavenging Cover (A) [74] and Scavenging Cover (B) [17], degrease the screw holes
of the Cylinder [73].
Ɣ Before mounting the Intake (CS51) [48], degrease the screw holes of the Cylinder [73].
Ɣ Reassemble the packings by ensuring the proper alignment of the holes.
Ɣ Pay attention to the directional property of the Cylinder Packing (C51) [75]. (At reassembly, match it
with the shape of the vent port.)
Ɣ Pay attention to the directional property of the Cover Packing (C51) [18]. (Assemble so that the lower
part of the Cover Packing (C51) [18] protrudes between Scavenging Cover (A)
[74] and Scavenging
Cover (B) [17].)
Ɣ When removing the Cylinder [73], remove all carbon deposits on the exhaust port and combustion
chamber by being careful not to scratch the cylindrical surface, and then carefully clean these parts by
using gasoline.
Ɣ Prevent the entry of foreign matter through the respective ports of the Cylinder [73] at reassembly.
Ɣ Before mounting the Cylinder [73], lightly apply 2-cycle oil to the cylindrical surface of the Cylinder [73]
and the periphery of the Piston (44) (M) [77].
Ɣ Fit the lip portion of the Intake (CS51) [48] into the groove of the Carburetor Insulator (C51) [50] when
mounting the Intake (CS51) [48] to the Carburetor Insulator (C51) [50].
-17-
• Cylinder and scavenging cover
Lip portion
Scavenging Cover (A) [74]
Intake (CS51) [48]
Intake Packing (C51) [47]
Cover Packing (C51) [18]
Scavenging Cover (B) [17]
Cover Packing (C51) [18]
Decomp. [45]
Cylinder [73]
Cylinder Packing (C51) [75]
Hex. Socket Hd. Bolt
M5 x 12 (Precote) [38]
Seal Lock Screw M4 x 10 [16]
Seal Lock Hex. Socket Hd. Bolt
M6 x 20 [37]
Spark Plug BPM-7A/BPMR7A [46]
Seal Lock Screw M4 x 10 [16]
Cab. Insulator Rubber [49]
Carburetor Insulator (C51) [50]
11. Disassembly and reassembly of the piston and piston ring
[Tools required]
Ɣ Long-nose pliers
Ɣ J-359 jig (No.6695741) (piston pin extraction tool ass’y)
Ɣ Hex. socket hd. bolt M5 x 12
Ɣ Round bar 9.8 mm in diameter (e.g., borer 10 mm in diameter)
(1) Disassembly
Ɣ Remove the two Circlips [78] with long-nose pliers.
Ɣ Insert a hex. socket hd. bolt M5 x 12 into the
pushing side of the Piston Pin [85], and then turn
the pin pullout bolt of the J-359 jig (piston pin
extraction tool ass’y) clockwise to pull out the
Piston Pin [85].
CAUTION: Do not scratch the Piston (44) (M) [77].
(2) Reassembly
Ɣ Do not reuse the Circlips [78].
Ɣ When removing the Piston (44) (M) [77], remove
carbon deposits on top of the Piston (44) (M) [77]
by being careful not to scratch the piston surface,
and then carefully clean the Piston (44) (M) [77] by
using gasoline.
Ɣ If the Piston Ring [76] does not move smoothly, remove carbon deposits on the ring groove of the
Piston (44) (M) [77] and Piston Ring [76], and then carefully clean these parts by using gasoline.
• Removing the piston
Hex. socket hd.
bolt M5 x 12
Pin pullout bolt
J-359 jig
(piston pin extraction tool ass’y)
-18-
Ɣ Mounting the piston
Piston (44) (M) [77]
Pin pullout bolt
Piston Pin [85]
Hex. socket hd. bolt
M5 x 12
Round bar 9.8 mm in diameter
(
e.
g
., borer 10 mm in diameter
)
Piston Pin Collar (C51) [79] Needle Bearing (A) [86]
Circlip mounting groove
Connecting rod small end
Ɣ Piston and piston ring
Piston Ring [76]
Piston (44) (M) [77]
Piston Pin [85]
Needle Bearing (A) [86]
Piston Pin Collar (C51) [79]
Circlip [78]
Connecting rod small end
Ɣ Insert the Piston Pin [85] by following the procedure below. (See “Mounting the piston.”)
(1) Insert the Piston Pin [85] into the Piston (44) (M) [77] by about 7 mm.
CAUTION: Be sure to support the flat portion (casting surface) of the Piston (44) (M) [77]
when using a hand press. Do not tilt the Piston Pin [85].
(2) Set the J-359 jig (piston pin extraction tool ass’y) to the Piston (44) (M) [77], and then set a hex.
socket hd. bolt M5 x 12 into the pushing side of the Piston Pin [85].
(3) Set Needle Bearing (A) [86] and the two Piston Pin Collars (C51) [79] to the connecting rod small
end, and then cover it with the Piston (44) (M) [77]. (Align the triangular arrow on top of the Piston
(44) (M) [77] with the direction of the exhaust port of the Cylinder [73].) Insert a round bar about
9.8 mm in diameter (e.g., borer 10 mm in diameter) into the Piston (44) (M) [77] opposite the side
where the Piston Pin [85] is inserted, in order to prevent Needle Bearing (A) [86] and the two
Piston Pin Collars (C51) [79] from becoming misaligned.
CAUTION: Mount the Piston Pin Collar (C51) [79] with its concave portion facing Needle
Bearing (A) [86].
(4) With the round bar 9.8 mm in diameter inserted, turn the pin pullout bolt of the J-359 jig (piston pin
extraction tool ass’y) clockwise, and then push in the Piston Pin [85] just before the circlip
mounting groove of the Piston (44) (M) [77].
CAUTION: Do not get the Piston Pin Collars (C51) [79] caught in other parts.
Ɣ Use long-nose pliers to fit the tip of the Circlip [78] (2 pcs.) into the groove of the Piston (44) (M) [77],
and then turn it until the Circlip [78] is completely mounted.
Ɣ Align the opening of the Piston Ring [76] (2 pcs.) with the knock pin of the Piston (44) (M) [77].
Ɣ After mounting the Piston (44) (M) [77], lightly apply 2-cycle oil to Needle Bearing (A) [86].
-19-
Engine Case (B) Ass’y [80]
Oil Seal [81]
Ball Bearing 6202C3 [82]
Crank Shaft [83]
Crank Case Packing (C51) [84]
Engine Case (A) Ass’y [87]
Rear Damper (C51) [88]
Seal Lock Hex.
Socket Hd. Bolt
M5 [32]
Seal Lock Hex.
Socket Hd. Bolt
M5 x 45 [35]
Seal Lock
Screw
M5 x 12 [33]
Spike [34]
Ɣ Engine case
12. Disassembly and reassembly of the engine case
[Tools required]
Ɣ Hex. bar wrench (5 mm)
Ɣ Phillips screwdriver
Ɣ Long-nose pliers
(1) Disassembly
Ɣ Use long-nose pliers to pull out the Rear Damper (C51) [88].
Ɣ Use a Phillips screwdriver to remove the two Seal Lock Screws M5 x 12
[33]
, and then remove the Spike
[34]
.
CAUTION: The threads of the Seal Lock Screws M5 x 12 [33] may be easily broken. Therefore, do not
tighten the screws too much.
Ɣ Use a 5-mm hex. bar wrench to remove the four Seal Lock Hex. Socket Hd. Bolts M5 [32] and two Seal
Lock Hex. Socket Hd. Bolts M5 x 45 [35]. Then remove the Engine Case (A) Ass’y [87], Engine Case
(B) Ass’y [80], and Crank Shaft [83].
Ɣ Remove Ball Bearing 6202C3 [82] and the Oil Seal [81] by pushing it out on the Oil Seal [81] side.
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Do not reuse the Oil Seal [81] and Ball Bearing 6202C3 [82] removed from the Engine Case (A) Ass’y
[87] and Engine Case (B) Ass’y [80].
Ɣ Do not reuse the Crank Case Packing (C51) [84].
Ɣ Do not reuse the Seal Lock Hex. Socket Hd. Bolts M5
[32]
and Seal Lock Hex. Socket Hd. Bolts M5 x 45
[35]
.
Ɣ Apply 50 to 100 mg of Piloknock Universal No. 0 of JX Nippon Oil & Energy between the lips of the Oil
Seal [81].
Ɣ Carefully clean the Crank Shaft [83] by using gasoline before mounting.
Ɣ Degrease the screw holes of the Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80] before
mounting. Do not get the Fuel Pipe [119] caught between the Engine Case (A) Ass’y [87] and Engine
Case (B) Ass’y [80] when mounting.
Ɣ Check the hole position of the Crank Case Packing (C51) [84] and mount it without misalignment.
(When mating the Engine Case (A) Ass’y [87] and Engine Case (B) Ass’y [80], confirm that the Crank
Case Packing (C51) [84] is properly mounted along the circumference of the engine case.)
Ɣ Cut off the protrusion of the Crank Case Packing (C51) [84] at the mating surface of the Cylinder [73]
after mounting.
CAUTION: Do not break the Crank Case Packing (C51) [84] when cutting it.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
-
27
-
28
-
29
-
30
-
31
-
32
-
33
-
34
-
35
Hitachi CS51EAP User manual
- Category
- Power chainsaws
- Type
- User manual
- This manual is also suitable for
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Related papers
-
Hitachi CS 33ED User manual
-
-
-
Hitachi CS 33EDT User manual
-
-
-
-
-
-
Other documents
-
Thule 156 User manual
-
PylePro PSTND35 Owner's manual
-
Subaru EC12 User manual
-
MQ Multiquip 3000-6000-7000-blade-flange-removal-p/n-18503-1 Operating instructions
-
Yamaha MAJESTY YP250 User manual
-
DAELIM S4 50cc User manual
-
Suzuki RM85 Owner's Service Manual
-
-
-
