Makita BHX2500CA Operating instructions

Brand: Makita

Model: BHX2500CA

Category: Engine

Type: Operating instructions

REPAIR MANUAL

BHX2500

BHX2500CA

PB-251.4

CONTENTS

Ⅰ.SPECIFICATIONS・・・・・・・・・・・・２

1.SPECIFICATIONS・・・・・・・・・・・・・・・・２

2.PART NAMES・・・・・・・・・・・・・・・・・・３

Ⅱ.PREPARATIONS・・・・・・・・・・・・・４

1.PREPARATIONS・・・・・・・・・・・・・・・・・４

2.NOTICE・・・・・・・・・・・・・・・・・・・・４

Ⅲ.DISASSEMBLY AND REASSEMBLY PROCEDURE・５

1.EQUIPMENT DISASSEMBLY ・・・・・・・・・・・・５

2.EQUIPMENT REASSEMBLY・・・・・・・・・・・７～１１

3.ENGINE DISASSEMBLY・・・・・・・・・・・・・・１２

4.ENGINE REASSEMBLY ・・・・・・・・・・・１３～２５

5.CARBURETOR DI

SASSEMBLY AND REASSEMBLY ・２６～２７

6.STARTER DISASSEMBLY AND REASSEMBLY・・・２８～３０

Ⅳ.MALFUNCTION AND REPAIRE ・・・・３１～３２

Ⅴ.CHECK AND RECONDITIONING・・・・・・・３３

Ⅵ.CRITERIA FOR RECONDITIONING ・・３４～３５

Ⅶ.NOTICE・・・・・・・・・・・・・・・・３６

Ⅷ.CARE AND STORAGE・・・・・・・・・・・３７

Ⅸ.

CHECK,DRAINAGE AND FEEDING OF ENGINE OIL

・・３８

3.SPECIAL TOOL FOR DISASSEMBLY・・・・・・・・・４

Ⅰ．SPECIFICATIONS

1.SPECIFICATIONS

Engine Blower

BHX2500/PB250.4

mm 350×231×368（13.8×9.1×14.5 in only for body）

kg 4.5（9.5 lbs only for body)

EH025F

Air-Cooled, 4-Stroke, Upright Single-Cylinder OHV Gasoline Engine

Piston Displacement

mL 24.5（1.49 cu,in）

Automotive Unleaded Gasoline

Fuel Tank Capacity

L 0.52（17.6 fl.oz）

Automotive Oil SAE 10W-30; Class SF or higher (Automotive 4-Cycle Engine Oil)

Capacity of Engine Oil

L 0.08（2.7 fl.oz）

Diaphragm Type

Breakerless Magneto

NGK CMR6A (Type C)

Recoil Starter (with decompression)

Forced Lubrication

Max Air Volume

/min

10.1（356 cu.ft/min）

Max Air Velocity

m/s 64.6（212 ft/s）

Volute Case Integrated Loop Handle (with rubber grip)

Trigger Lever, Cruise Control Lever

One Blower Nozzle (Round), One Blower Tube, Tool (Box Wrench)

Instruction Manual

Type

Dimensions(LXWXH)

Dry Weight

Standar

d Accessories

Model

Type

Fuel

Engine Oil

Carburetor

Ignition System

Engine Speed Control Lever

SPECIFICATIONS

Spark Plug

Starting System

Lubrication

Handle

Product Name

Engine

Performance

Operating Part

2.PART NAMES

DESIGNATION OF PARTS DESIGNATION OF PARTS

1. Stop switch

2. Main Handle

DESIGNATION OF PARTS DESIGNATION OF PARTS

7. Starter Handle

8. Fuel Tank

9. Fuel Tank Cap

10. Muffler

11. Assist Handle

12. Cruise lever

13. Screw

14. Protector

17. Oil Cap

18. Blower Tube

5. Air Cleaner Cover

6. Choke Lever

3. Trigger Lever

4. Primer Pump

19. Blower Nozzle A

20. Blower Nozzle B

21. Elbow

22. Vacuum Pi

pe A

23. Vacuum Pipe B

24. Vacuum Pipe C

25. Arrow Mark

26. Dust Bag

15. Plug Cover

16. Spark Plug

Optional

Optional (Vacuum Set)

Ⅱ．PREPARATIONS

1.PREPARATIONS

(1)Workbench

(2)Tool for disassembly and reassembly

(3)Wash-pan

(4)Wash oil (light oil, gasoline, etc)

(5)Automotive 4-stroke engine oil, grease

(6)Liquid packing

(7)File, sand paper

(8)Waste

2.NOTICE

(1) Use the standard tools properly.

(2) While disassembling the engine blower, memorize the locations of individual parts

so that they can be reassembled correctly.

Attach a t

ag to a part you are uncertain about its mounting position.

(3) Use boxes for keping disassembled parts in a group.

(4) To prevent any loss and wrong reassembly of screw bolts and nuts, try to assemble

each group of disassemble parts temporarily.

(5) Handle disassembled parts carefully, and clean them with wash oil.

(6)

After removing gaskets, remove extraneous material clearly from the gasket placed palaces.

(7)

Use an impact driver for a screw bolt and screw, etc. that are difficult to be unfastened.

(8) Use new gaskets when reassembling.

(9) After reassembling each of the rotatable main parts, rotate by hand to test it for

(10)After the completion of reassembly, rotate the rotatable main parts by hand to test

SPECIAL TOOL FOR DISASSEMBLY

Part number：５６０９００２０００

Tool name：ＴＯＯＬ

Work：Flywheel Puller

bad movements and abnormal noises.

them for defects and looseness.

Ⅲ．DISASSEMBLY AND REASSEMBLY PROCEDURE

1.EQUIPMENT DISASSEMBLY

Step Part of remove Procedure Fastener PCS

Notice

Special tool

1)Unscrew the CAP,OIL.

Keep contamination or dust off

the CAP,OIL and gauge.

2)Drain the engine oil.

Screw the CAP,OIL onto the oil tank.

1)Drain the fuel.

2)Remove the fuel tube.

The fuel will spout if the fuel tube

is removed with the fuel tank filled

Remove the COVER,AIR CLEANER.

M5X14mm 1

Remove the AIR CLEANER ELEMENT.

Keep contaminant or dust off

the AIR CLEANER ELEMENT.

1)Remove the GUARD,OIL.

5X16mm 3

M4X16mm 2

1)Remove the CASE 1,VOLUTE.

5X16mm

2)Remove the GRIP.

Urea screw 1

5X16mm 1

Remove the CRUISE CONTROL LEVER.

4X16mm 1

5)Remove the LEVER,THROTTLE.

6)Remove the CONTROL CABLE.

7)Remove the WIRE.

8)Remove the STOP SWITCH.

9)Remove the RUBBER,FRICTION.

1)Remove the IMPELLER.

M6X20mm

2)Remove the engine.

M5X30mm 3

7 TANK,FUEL

1)Remove the TANK,FUEL.

5X16mm 3

CASE 1,VOLUTE5

ENGINE6

2)Remove the COVER,ENGINE.

3)Remove the PROTECTOR.

ENGINE OIL1

FUEL2

COVER,AIR CLEANER3

COVER,ENGINE4

with fuel.

GRIP

SWITCH COMPL

RUBBER,FRICTION

CASE 2,VOLUTE COMPL

CONTROL CABLE

SCREW ASSY

IMPELLER COMPL

SCREW ASSY

CASE 1,VOLUTE ASSY

TAPPING SCREW

SNAPRING,OUTER

PROTECTOR

GASKET

SCREW

TAPPING SCREW

WASHER

SPRING

SHAFT

TAPPING SCREW

COVER,PLUG

GUARD,OIL

CAP,TANK FUEL ASSY

SCREW ASSY

TUBE

HOSE CLAMP

FILTER

TAPPING SCREW

WASHER

TANK,FUEL

COVER,ENGINE

LEVER,CRUISE

SPRING

TAPPING SCREW

LEVER,THROTTLE

Deal Drawing of Equipment

2.EQUIPMENT REASSEMBLY

Equipment reassembly procedure

1.Notice

・ Clean parts completely.

・ Replace screws with new ones if necessary.

・

Tighten up the tightening torque specified parts according to the specified tightening torque.

2.Tightening torque of each part.

No. Tightening part

Tightening

torque

(kg･cm)

The kind of screw pcs

TANK,FUEL

～CASE 2,VOLUTE

5×16 TAPPING SCREW

(Setting of washer)

3pcs

ENGINE

～CASE 2,VOLUTE

+10

-5

M5×30 W,SW SCREW 3pcs

IMPELLER

～FLYWHEEL

+10

-5

M6×20 W,SW SCREW 2pcs

CASE 1,VOLUTE

～CASE 2,VOLUTE

5×16 TAPPING SCREW 10pcs

COVER,ENGINE

～CASE 2,VOLUTE

5×16 TAPPING SCREW 3pcs

COVER,ENGINE

～RECOIL STARTER

～ENGINE

+10

-5

M4×16 W,SW SCREW 2pcs

COVER,AIR CLEANER

～PLATE,AIR CLEANER

5～10

M5×14 W,SW SCREW

1pc

（ By manual

acceptable）

Be careful not to cause the wires to come away from the groove when mounting the engine.

3.ENGINE DISASSEMBLY

Step Part to remove Procedure Fastener PCS

Notice

Special tool

Remove the PLATE,AIR CLEANER.

M5X8mm 2

Fasten with the CARBURETOR.

Remove the breather-pipe and the

return pipe from the cylinder side.

Use a small flat-head screwdriver

for easy removal.

Small flat-head

screwdriver

M5X18mm 2

M5X14mm 1

1)Remove the PLATE,SEPARATOR.

Be sure to pull the PLATE,SWPARATOR

by its body. Do not pull the

PLATE,SEPARATOR by the square

pipe to avoid its breakage.

2)Remove the GASKET,SEPARATOR.

Remove the PLATE,CHECK VALVE.

(with the CHECK VALVE).

Use a small flat-head screwdriver

at the hook of the PLATE,CHECK VALVE

to remove it.

Small flat-head

screwdriver

4)CHECK VALVE(1)

Do not let the CHECK VALVE(1)

missing.

3 MUFFLER,EXHAUST

1)Remove the MUFFLER,EXHAUST.

M5X40mm 2

1)Remove the STARTER REWIND.

M4X16mm 2

2)Remove the PULLEY.

Hit with a hammer a metal bar supported

by the hand in one of the holes of the PULLEY

as shown in the figure (right-handed screw).

Metal bar,

hammer

1)Remove the COIL.

M4X20mm 2

2)Remove the FLYWHEEL.

M6X16mm 1

Using a flywheel puller, rotate

the conter shaft cockwise.

Flywheel

puller

6 PLUG SPARK

1)Remove the PLUG SPARK.

16mm

plug wrench

7 CASE,OIL

1)Remove the CASE,OIL.

M5X18mm 4

Tap the recoil side of the OIL CASE

using a plastic or wooden hammer.

Plastic or

wooden hammer

1)Remove the TUBE,OIL.

Hold TUBE,OIL root and pull out TUBE,OIL

with the aid of a small flat-head screwdriver

Small flat-head

screwdriver

2)Remove the RETAINER PLATE.

M4X10mm 1

Do not let the LEAD VALVE missing.

9 ROCKER COVER

1)Remove the ROCKER COVER.

M5X16mm 3

10 COVER,CAMGEAR

1)Remove the COVER,CAMGEAR.

M5X14mm 3

1)Remove the SHAFT,CAMLIFTER.

Position the cam peakportion

down.

2)Remove the CAMLIFTER.

3)Remove the SHAFT,CAMGEAR.

4)Remove the CAMGEAR.

5)Remove the PUSH ROD.

1)Remove the ROCKER SHAFT.

Pull it out by holding with a pair of pincers the

shaft seen between the intake and exhaust ROCKER ARMS.

2)Remove the ROCKER ARM.

13 CRANK CASE

1)Remove the CRANK CASE.

M5X14mm 8

Tap the recoil side of the CRANKCASE

using a plastic or wooden hammer.

14 CRANKSHAFT COMPL

1)Remove the CRANKSHAFT COMPL.

Do not damage the OIL SEAL.

1)Remove the RETAINER,SPRING.

Support the VALVE from the inner side

of the CYLINDER, push RETAINER,SPRING

and slide it.

2)Remove the VALVE.

3)Remove the SPRING,VALVE.

1)Remove the CLIP.

Privent dust from getting in the BEARING

at the ROD,CONNECTING small end.

2)Remove the PIN,PISTON.

3)Remove the RING,PISTON.

Widening the open end of the ring

might break it.

VALVE15

PISTON16

CAMGEAR11

ROCKER ARM12

3)Remove the INSULATOR.

INSULATOR1

AIR CLEANER BREATHER

RETAINER PLATE8

STARTER REWIND4

FLYWHEEL5

Plastic or

wooden hammer

4.ENGINE REASSEMBLY

Engine reassembly procedure

1.Notice

・ Clean parts completely specifically the PISTON, CYLINDER, CRANKCASE, CRANKSHAFT

and BEARINGS.

・

Remove completely all the carbon deposit from the COMBUSTION CHAMBER and the PISTON top.

・

Test the lip of the OIL SEALS for damage. Replace damaged OIL SEALS with new ones.

Apply oil over the lip before reassembly.

・ Replace all GASKETS with new

ones.

・ Replace PINS and SCREWS with new ones if necessary.

・

Tighten up the tightening torque specified parts according to the specified tightening torque.

・ Apply 4-stroke engine oil over the rotating portions and sliding surfaces.

・ Check and adjust the clearances.

・ After reassembling each of the rotatable main parts, rotate by hand to test it for

2.Tightening torque

No. Tightening part

Tightening torque

(kg･cm)

Screw PCS

CRANKCASE

～RETAINER PLATE

+10

M4×10 SW SOCKET １

CYLINDER BLOCK

～CRANKCASE

±10

M5×14 SOCKET ８

CRANKCASE

～CASE,OIL

+10

-5

M5×18 W,SW SCREW ４

4 COVER,CAMGEAR 45

+10

-5

M5×14 W,SW SCREW ３

5 IGNITION COIL 20

+20

M4×20 W,SW SCREW ２

6 FLYWHEEL 105

±15

M6×16 W,SW BOLT １

R O C K E R A R M A D J U S T

SCREW～NUT

+15

M5 NUT ２

8 ROCKER COVER 45

+10

-5

M5×16 W,SW SCREW ３

9 MUFFLER EXHAUST 75

+15

-5

M5×40 W SOCKET ２

10 PLUG,SPARK 110

±20

M10×P1.0 １

11 INSULATOR 45

+10

-5

M5×18 W,SW SCREW

M5×14 W,SW SCREW

２

１

PLATE,AIR CLEANER

～CARBURETOR

～INSULATOR

+20

M5×68 SUS SCREW ２

13 PIPE,OIL 45

+10

-5

M5×12 W,SW SCREW １

14 RECOIL STARTER 15

+10

-5

M4×16 W,SW SCREW ２

bad movements and abnormal noises.

NO. Part name Procedure

NEEDLE ROLLER BEARING

ROD LARGE AND SMALL ENDs

(1)

Apply grease over the inside of the BEARINGS and press the PIN into it.

PISTON and

CRANKSHAFT COMPL

(1) Apply 4-stroke engine oil over the PISTON RINGS and OIL RING after

placing them.

・Position the open end of TOP RING and

SECOND RING in the opposite direction.

・OIL RING assembly order

①SPACER

②LOWER SIDE RAIL

③UPPER SIDE RAIL

・

Position each open end of

different position 120-degree.

①

②

③

TOP RING

SECOND RING

White mark:right

OIL RING

CLIP

PIN PISTON

OIL SEAL(L)

Apply greas e ov er

the inner part.

CLIP

WOODRUFF KEY

OIL SEAL(S)

Apply grease over the

inner part.

the parts in a respectively

NO. Part name Procedure

CYLINDER BLOCK

VALVE SPRING

～RETAINER,SPRING

(1) Apply 4-stroke engine oil over the inner wall of the CYLINDER, the

sliding surface of the PISTON and the valve holes before reassembly.

(2) Apply the oil over the valve guide hole before inserting VALVE.

To insert VALVE, reassemble SPRING and RETAINER as shown below,

insert VALVE into the RETAINER hole and slide R

ETAINER while

pushing SPRING.

SPACER reassembling position

RETAINER SPRING

VALVE SPRING

CYLINDER BLOCK ASSY

SPACER

CHECK VALV

INTAKE VALVE

EXHAUST VALVE

Slide the

SPRING down.

Slide the

RETAINER,SPRING.

NO. Part name Procedure

CYLINDER BLOCK

～CRANKCASE

(1) Join CYLINDER BLOCK and CRANKCASE on each housing blower

installation surface.

＜CRANKCASE upper side＞

･Check that liquid packing

(TB1216)is applied evenly

over CRANKCASE(hatched surface)

before reassembly.

＜Tightening order(important)＞

SOCKET HEAD BOLT

M5*14(8 pcs)

Tightening torque

10 ㎏･㎝

CRANKCASE COMPL

CYLINDER BLOCK SET

NO. Part name Procedure

CRANKCASE

～CASE,OIL

CASE,OIL

SCREW

W,SW M5*18(4 pcs)

Tightening torque

45 ㎏･㎝

+10

-5

WEIGHT,OIL

TUBE,OIL

SOCKET HEAD BOLT

SW M4*10(1 pcs)

Tightening torque

30～40 ㎏･㎝

RETAINER

PLATE

LEAD VALVE

GASKET,CASE

OIL FILLER HOLE

Attanch LEAD VALVE

with the cut-out

facing to OIL

FILLER HOLE.

Cut-out

NO. Part name Procedure

FLYWHEEL (1)

Degrease CRANKSHAFT and FLYWHEEL tapered portion completely before joining them.

(2) Align FLYWHEEL key groove with CRANKSHAFT key.

IGNITION COIL

GROMMET

～CAP,PLUG

(1) Attach SPRING,PLUG CAP to the HIGHT-TENSION CODE.

(2) Insert the HIGHT-TENSION CODE with the SPRING,PLUG CAP into

PLUG CAP.

(3) Position the holes of SPRING, PLUG CAP and PLUG CAP in the

same direction.

FLYWHEEL CP

BOLT ASSY

W,SW M6*16(1 pc)

Tightening torque

105±15 ㎏･㎝

CAP,PLUG

SPRING,PLUG CAP

IGNITION

COIL

SCREW ASSY

W,SW M4*20(2 pcs)

Tightening torque

20 ㎏･㎝

+20

･Air gap：0.3mm

PLUG CAP

THICKNESS GAUGE

IGNITION

COIL

FLYWHEEL

NO. Part name Procedure

(1) Align the mark punched on FLYWHEEL(key position groove) with the

timing mark on IGNITION COIL(Do not let FLYWHEEL move).

CAMGEAR

(2) Join CAMGEAR to CRANKGEAR with CAM top facing down vertically

(use the timing mark for reference).

timing mark

CAMGEAR ASSY

SHAFT CAMGEAR

CAM top(facing down vertically)

Timing mark

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Makita BHX2500CA Operating instructions

Brand: Makita

Model: BHX2500CA

Category: Engine

Type: Operating instructions

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Makita BHX2500CA Operating instructions

Makita BHX2500CA Operating instructions

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