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DCS230T-TE


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T            ECHNICAL INFORMATION
    Models No.                       DCS230T/ PS220TH
                                                                                                                    NEW TOOL
                                                                                                                      P 1 / 23

    Description                                                                                          W
                                     Engine Chain Saw 250mm

CONCEPT AND MAIN APPLICATIONS
   Primarily targeted at professionals who frequently prune
   fruit trees or street trees, these new models have been developed
   as "the lightest-in-the world*" top handle engine chain saws.
   (*Note: according to our investigation, in the category of engine                       H
    chain saw and at the date of August, 2004)
   Other benefits are:
     Inertia chain brake                                                                                 L
     Automatic adjustable chain oiling
     Easy start system
     Idling start                                                                                   Dimensions: mm (")
                                                                                               Length (L)     242 (9-1/2)
   DCS230T is Makita brand model.
   PS220TH is Dolmar brand model.                                                              Width (W)      215 (8-1/2)
                                                                                               Height (H)       202 (8)



 Specification
                                                                                Continuous Rating (W)
              Voltage (V)           Current (A)       Cycle (Hz)                                             Max. Output(W)
                                                                               Input           Output
                                                                                                                  740


    Standard guide bar: mm (")                                250 (9-7/8)
                                          Pitch (")                  1/4
    Chain blade




                  Carving bar
                                          Gauge (")                 0.050
                                          Pitch (")                  3/8
                  Sprocket nose bar bar
                                          Gauge (")                 0.050
    Displacement: ml                                                 22.2
    Max output: kw                                                   0.74
    Fuel tank capacity: l                                            0.2
    Chain oil tank capacity: l                                       0.19
    Power head weight: kg (lbs)                                    2.5 (5.5)



 Standard equipment
   Chain blade 250mm .......... 1 (25AP-60E for Carving bar or 91VG-40E for Sprocket nose bar)
   Guide bar ........................... 1 (Carving bar or Sprocket nose bar)
   Guide bar scabbard ............ 1
   Wrench 13-16 .................... 1
   Note: The standard equipment for the tool shown above may differ by country.

 Optional               accessories
   Chain blade 250mm (25AP-60E for carving bar or 91VG-40E for sprocket nose bar)
   Guide bar (Carving bar or Sprocket nose bar)
   Chain oil
   Engine oil
                                                                                                                                  P 2 / 23
Features      and benefits

 "The Lightest in the World" Design                                Top Handle                               Sprocket nose bar
  Weighs Only 2.5kg (5.5lbs).                            Optimum for pruning fruit trees
                                                                                                            and Carving bar
                                                         or street trees                                    are both available.
Lightest in the world* in the category of engine
chain saw, providing ultimate handling ease.
Especially in long continuous tree pruning,
hand and arm fatigue will be minimum,
increasing operation efficiency to a great extent.
(*at the time of August, 2004, according to
  our investigation)




          Easy Start System                                                                           Idling Start
The force required to pull starter rope                                                 Employment of the "Lift-Up" type
has been reduced to 60% of chain saws                                                   carburetor allows idling start to prevent
without Easy Start system.                                                              the blade run at start-ups.
(See page 4 for details.)                                                               (See page 4 for details.)




Comparison         of products
                                              Makita/ DOLMAR                                     A                            B
                     Model No.
                                        DCS230T               DCS330TH
  Spec.                                                                                          A                            B
                                        PS220TH               PS3300TH
Standard guide bar: mm (")             250 (9-7/8)       300 (11-3/4)/ 350 (13-3/4)         250 (9-7/8)                 250 (9-7/8)
Displacement: ml                          22.2                     32.3                        25.4                        26.9
Max output: kw                            0.74                      1.0                        N/A                         0.91
Fuel tank capacity: l                      0.2                     0.25                        0.23                        0.24
Chain oil tank capacity: l                0.19                    0.17                         0.16                        0.16
Ignition system                           CDI                     CDI                          CDI                         CDI
Automatic adjustable chain oiling         Yes                     Yes                          Yes                         Yes
Inertia chain brake                       Yes                     Yes                          Yes                         Yes
                  Pitch (")             3/8, 1/4                   3/8                       3/8, 1/4                    3/8, 1/4
Chain blade
                  Type                91VG, 25AP                 91VG                      91VG, 25AP                  91VG, 25AP
                  Length               242 (9-1/2)            257 (10-1/8)                 265 (10-3/8)                 251 (9-7/8)
Dimensions*:
                  Width                215 (8-1/2)             222 (8-3/4)                  220 (8-5/8)                 215 (8-1/2)
       mm (")
                  Height                 202 (8)               215 (8-1/2)                  220 (8-5/8)                211 (8-5/16)
Power head weight: kg (lbs)             2.5 (5.5)               3.6 (7.9)                    2.9 (6.4)                   2.8 (6.2)
Total gross weight**: kg (lbs)          3.2 (7.1)                  ---                       3.7 (8.2)                   3.6 (7.9)
                                    Chain blade           Chain blade                 Chain blade                 Chain blade
                                    Guide bar             Guide bar                   Guide bar                   Guide bar
Standard equipment                  Guide bar scabbard    Guide bar scabbard          Guide bar scabbard          Guide bar scabbard
                                    Wrench                Wrench                      Wrench                      Wrench
                                                                                      Slotted screwdriver         Slotted screwdriver
                                                                                      (for carburetor adjustment) (for carburetor adjustment)

 *Excludes guide bar and chain blade.
**Includes guide bar, chain blade and fuel.
                                                                                                           P 3 / 23

Comparison       of products (cont.)
Performance Comparison
For performance comparison with Model A of the competitor A and Model B of the competitor B,
we carried out the following test:
[1] Cut 50x50mm timbers, and compared;
   1) the number of timbers cut on a full fuel tank
   2) the fuel consumption (the numbers of timbers cut per cc)
   Note: We chose 50x50mm timber as the test material because cutting 30 to 50mm dia. olive tree will be
           the main application of the new products.
[2] Pulled the recoil starter rope, and measured the force required to start the engine.

Note: Numbers in the graphs below are relative values when the capacity of Model A (for European countries) of
      the competitor A is indexed at 100.

   [The number of timbers cut on a full fuel tank]

                                                 Few                  Many

      Makita DCS230T/ PS220TH                        120            685 timbers

              Competitor A Mod. A                    100

              Competitor B Mod. B                    120

                                     0          50          100         150


   [Fuel consumption (the numbers of timbers cut per cc)]

                                                 Few                  Many

      Makita DCS230T/ PS220TH                        140                3.4 timbers

              Competitor A Mod. A                    100

              Competitor B Mod. B                    115

                                     0          50          100         150


   [Force required to pull the starter rope to start the engine]
                                                 Heavy                Light

      Makita DCS230T/ PS220TH                        110          69N

              Competitor A Mod. A                    100

              Competitor B Mod. B                      95

                                     0          50          100         150
                                                                                                                  P 4 / 23

Makita       advantages
Lift-Up Type Carburetor
For starting cold engine, it is necessary to produce denser fuel/air mixture and to supply it to combustion chamber.
Described below is the difference in the way to produce denser fuel/air mixture between Lift-Up Type Carburetor
and the conventional carburetor.

             Conventional Carburetor                                        Lift-Up Type Carburetor
  Denser fuel/air mixture is made by reducing                 Denser fuel/air mixture is made by increasing absolute
  the amount of air. Choke shutter is closed                  amount of fuel, not by reducing the amount of air.
  in order to reduce the amount of air flow.                  For that purpose, fuel is supplied from two fuel nozzles.

                           Amount of air reduced
                           by choking                         No need to choke                          Fuel supplied from
                                                              the air flow to                           sub fuel-nozzle
                                                              produce denser
                                                              fuel/air mixture.                         Fuel supplied from
                                                                                                        main fuel-nozzle
             Air    Fuel                                                                Air   Fuel

  Because the amount of fuel/air mixture is a little,         Because the amount of fuel/air mixture is much enough,
  it is very hard to get idling start. Therefore, operator    idling start can be done without opening the throttle.
  need to open the throttle.                                  And the fuel supply can be automatically reduced to an
  However, as the throttle adjustment depends on              optimum fuel/air supply by opening the throttle.
  operator's skill, the blade will run at start-ups or the    Thus operator need not to do troublesome throttle control.
  engine won't start if an unskilled operator opens the
  throttle excessively.


Easy Start
                                                                    Crankshaft
As described below, addition of a Damper Spring
to the recoil starter reduces the force required to
pull the starter rope to 60% of the engine with
conventional recoil starter, ensuring Easy Start.


                                                                    Damper spring



       Conventional Recoil Starter                                Recoil Starter with Damper Spring

              High resistance to operator hand                                    resistance reduced by 40%

       Piston




     Crank                                                                                           Force required
                                                                                                     to pull: 60%
                                                                                                Support force from
                                                                                                damper spring: 40%
 Recoil starter                                                                               Damper spring

  Operator has to keep on pulling the starter rope      Pull of the starter rope winds the damper spring, and when the
  to the full because of resistance of air pressure     pulling force exceeds a certain value, the force stored in the spring
  in the cylinder.                                      is released to rotate the crankshaft.
                                                        Owing to this support force from damper spring, the power
                                                        required to pull the starter rope reduces to 60% of the engine
                                                        with conventional recoil starter.
                                                                                                              5 / 23

[II] Disassembly/Assembly/Adjustment
1. Necessary Repairing Tools

  Tool No.                     Description                                             Use for
                                                                Disassembling/assembling kickback brake
   1R003        Retaining Ring Pliers ST-2N                     (inertia chain brake) system

   1R028        Bearing Setting Tool 20-12.2

   1R034        Bearing Setting Plate 12.2                      Press-fitting Bearing to Crankshaft

   1R048        Drill Chuck Remover 11

   1R091        Copper Round Bar 20-100                         Removing Flywheel

   1R127        Air Tightness Tester                            Testing Carburetor

   1R170        T-type Hex Wrench 3-127                         Removing/installing M4 Hex socket head bolt

   1R171        T-type Hex Wrench 4-130                         Removing/installing M5 Hex socket head bolt

   1R229        1/4" Hex Shank Bit for M5                       Removing Engine

   1R269        Bearing Extractor                               Removing Bearing from Crankshaft

                13mm Hex Socket Bit
                                                                Removing/installing Clutch and Flywheel
                Impact Driver (6990D, 6916D or the like)

                Iron Hammer                                     Removing Flywheel

                0.3mm Thickness Gauge                           Fixing and adjusting Ignition coil complete

                0.7mm Spark Plug Gauge                          Adjusting spark gap of Spark plug



2. Lubrication/Sealing
After you have disassembled the following parts, do lubrication or sealing as instructed below.

Needle bearing on clutch drum: Apply Makita grease N No. 2.
Spiral spring of recoil starter: Apply Makita grease N No. 2.
Engine: Apply Three bond 1215 to the contact surface between Crankcase and Cylinder.
                                                                                                                        6 / 23

3. Disassembly/Assembly
CAUTION: Be sure to remove gasoline and saw chain from the machine for safety before repair/ maintenance!
         Refer to the instruction manual for detailed information on how to remove or adjust saw chain.
IMPORTANT: When replacing Oil pump, also replace chain oil by fresh one.
3-1. Clutch Section
DISASSEMBLY
1) Clutch can be easily removed using Impact driver without locking Spindle.
2) Do not remove Spark plug because Clutch is removed using compression resistance.
   CAUTION: Be sure to turn off Engine stop switch to avoid injury from accidental engine startup.
3) Attach 13mm hex socket bit to Impact driver. Clutch is left-handed. Therefore, remove Clutch by turning the hexagonal
   portion in the center of Clutch clockwise with the Impact driver. (Fig. 1)
                                                                  Fig. 1                        Fig. 2
ASSEMBLY
                                                                                                  Flat washer 8
1) Apply Makita grease N No. 2 to the Needle bearing on
   Clutch drum, and insert Clutch drum in Crankshaft.
2) Set Flat washer 8 in place so that the chamfered side of
   the washer faces the engine side. (Fig. 2)
3) Assemble Clutch to Crankshaft first by turning it                                   loosen
   counterclockwise by hand, then turning counterclockwise
   for one second with Impact driver. (Fig. 1)                             tighten




3-2. Inspection of Clutch Drum
                                                                  Fig. 3                        Fig. 4
1) If the sprockets are dirty or worn down, clean them or
   replace Clutch drum by new one. (Fig. 3)
2) At the same time, check the drive links of saw chain
   for damage or wear. And if necessary, replace them
   by new ones. (Fig. 4)




3-3. Oil Pump Section
DISASSEMBLY
1) Remove Worm gear by turning counterclockwise with thin screwdriver. (Fig. 5)
2) Unscrew 4x18 Tapping screw, and remove Oil pump cover and Chain slider (L).
3) Remove two M4x12 Pan head screws. While levering up Connector a little bit,
   pull off Connector and Oil tube from Oil pump. Now Oil pump can removed. (Fig. 6)
   Note: Be sure to replace Oil pump entirely by new one.
4) Check if Connector and Oil tube is cracked or clogged and if Spring (oil filter) is clogged. (Fig. 6)
Fig. 5                                                   Fig. 6

                                      Worm gear               Oil pump
                                                                                                            Connector




                                                                            Oil tube                     Spring
                                                                                                                           7 / 23

3-3. Oil Pump Section (cont.)
ASSEMBLY
1) Fasten two M4x12 Pan head screws, first A then B so that Worm gear does not touch Oil pump. (Fig. 7)
2) Do not forget to set Flat washer 10 in place. (Fig. 7)
3) Install Oil pump cover and Worm gear, first Oil pump cover, then Worm gear.
4) After installation of Worm gear, make sure that Worm gear can be turned easily by hand.
3-4. Adjusting the Flow of Chain Oil
The flow of chain oil can be adjusted by turning the adjusting screw on the bottom of the machine using the slotted
screwdriver portion of Wrench 13-16 supplied.
Turn clockwise to increase the flow, and counterclockwise to decrease. (Fig. 8)
Fig. 7                                                                   Fig. 8
                                                Flat washer 10




   Pan head screw
          M4x12
                                                                                    Increase             Decrease




3-5. Ignition System
INSPECTION OF PLUG CAP                                                          Fig. 9
1) Remove Plug cap from Spark plug. Then using circuit tester, check the
   electrical conduction between Plug cap spring and the ground (earth)           Ignition coil
   terminal of Ignition coil complete. If the value of electrical resistance      complete                              Plug cap
   is about 7k ohms, the conduction is normal. (Fig. 9)

2) If there is no or unstable electrical resistance, check if Plug cap spring
   is properly connected with the ignition cable of Ignition coil complete.
   Lubricate the inside of Plug cap using aerosol spray lubricant, and then
   pull the ignition cable and Plug cap together spring out of Plug cap
   using pliers. (Fig. 10)
                                                                                  Ground (earth)
                                                                                  terminal
3) Check if Plug cap spring is properly connected with the ignition cable.
   If not, connect in the correct way as described below in 4).
   Also check if Plug cap is cracked. If cracked, replace it by new one.   Fig. 10

4) Install Plug cap spring on the ignition cable of Ignition coil complete                                     Ignition cable
   by piercing the needle portion of the spring in the center of the cable.
   While taking care not to let Plug cap spring fall off the cable, grab the       Aerosol spray
   cable with pliers and pull the spring back into Plug cap. (Fig. 11)             lubricant

5) Check if Plug cap spring is properly connected with the ignition cable
   of Ignition coil complete using circuit tester as described above in 1).
   Defective connection can cause weak or no spark at Spark plug.                                                      Plug cap

                                                                                Fig. 11

                                                                                  Pierce in the center          Plug cap spring
                                                                                  of ignition cable.




                                                                                                         Plug cap


                                                                                                   Pull with pliers.
                                                                                                                     8 / 23

3-5. Ignition System (cont.)
INSPECTION OF SPARK PLUG                                                      Fig. 12
1) Remove Plug cap, and remove Spark plug with supplied Wrench 13-16.
   Note: If Spark plug is wet with fuel, wipe it off with a clean cloth and       Center electrode
   dry Spark plug with power blower.                                                                        0.6 - 0.7mm
2) Remove carbon deposits on the center electrode and the ground
   electrode of Spark plug using wire brush.
3) Adjust the spark gap to 0.6-0.7mm by inserting a 0.7mm Spark plug              Ground electrode
   gauge in the spark gap. (Fig. 12)
4) Check if the spark occurs in the spark gap as described below:
   Install Plug cap on Spark plug, touch the threaded portion of the plug
   to the engine block, and then pull Recoil starter rope.
5) If no spark occurs, check the electrical conduction as described above
   in 1) of CHECKING PLUG CAP.                                                 Spark gap = the distance between the center
   And if the conduction is normal, replace Spark plug by new one and                   electrode and the ground electrode
   re-check for a spark in the spark gap.

3-6. Removal/Installation of Ignition Coil Complete
REMOVAL
1) Before removing Ignition coil complete, remove Starter case, pull Plug cap off from Spark plug and pull the ground
   (earth) wire off from the terminal on Ignition coil complete. (Fig. 13)
2) Remove two M4x20 Hex socket head bolts. Now Ignition coil complete can be removed. (Fig. 14)
   Note: Be careful not to lose two Spacers through which the Hex socket bolts are inserted.
Fig. 13                                                          Fig. 14



    Flywheel




                                                                           Spacer
          Ground (earth) terminal   Ground (earth) wire                    (2pcs)       M4x20 Hex socket head bolt (2pcs)


INSTALLATION
1) Put Spacers and Ignition coil complete in place, and pretighten M4x20 Hex socket head bolts. Do not tighten the bolts
   securely in this step. Insert a 0.3mm thickness gauge between Ignition coil complete and the magnet portion of Flywheel.
   Ignition coil complete will stick to the magnet portion of Flywheel. Then tighten the bolts securely.
2) Remove the thickness gauge, then turn Flywheel to make sure that Ignition coil complete does not touch Flywheel.

3-7. Inspection/Replacement of Stop Switch
INSPECTION                                                                        Fig. 15
1) Remove Top handle cover by removing four 4x18 Tapping screws.
                                                                                                                Switch
2) Using circuit tester, check the electrical conduction between the terminals.
   Stop switch is normal if the terminals are not conducted with the engine
   turnded on and conducted with the engine turned off. (Fig. 10)
                                                                                                          9 / 23

3-7. Inspection/Replacement of Stop Switch (cont.)
3) Using circuit tester, also check the conduction between    Fig. 16
   the engine block and the terminal connector of the
   ground (earth) wire of Ignition coil complete. (Fig. 16)
   At the same time, check wrong wiring, loose screws,
   loose connections or broken wires.




                                                                                    Terminal connector of
                                                                                    the ground (earth) wire
                                                                                    of Ignition coil

REPLACEMENT                                                   Fig. 17
1) Disconnect lead wires from Switch. Now Switch can be
   removed by pushing from the inside of Top handle cover.     Lead wires
2) Route the two lead wires (black and red) under the two
   fuel tube. (Fig. 17)
                                                               Fuel tubes



3-8. Disassembling/Assembling Flywheel                        Fig. 18

DISASSEMBLING                                                           Flywheel
1) Flywheel can be removed easily with Impact driver
   without locking Piston as well as Clutch. (Fig. 18)
2) Do not remove Spark plug because Clutch is removed
   using compression resistance.
   CAUTION: Be sure to turn off Engine stop switch              Turn Hex nut M8
   to avoid injury from accidental engine startup.              counterclockwise.

3) Attach 13mm hex socket bit to Impact driver.           Fig. 19
   Then remove Hex nut M8 by turning counterclockwise
   with the Impact driver. (Fig. 19)
   Note: Be sure that Hex nut M8 is right-handed.
4) Remove Flywheel by hitting Crankshaft hard with Copper
    round bar 20-100 (1R091) and iron hammer. (Fig. 19)
5) Two Ratchets on Flywheel can be removed by removing
   M5x12 Hex socket button bolts with T-type hex wrench
   3-127 (1R170).
                                                                 1R091



ASSEMBLING                                                    Fig. 20
1) Install two Torsion spring 15 on Flywheel as illustrated
   on Flywheel, then fasten two Ratchets to Flywheel with
   Hex socket button bolts. (Fig. 20)
2) Fitting the protrusion (key) on the center hole of
   Flywheel to the groove in Crankshaft, assemble Flywheel
   to Crankshaft.
3) Set Spring washer 8 in place, then fasten Hex nut M8 to
   Crankshaft by turning clockwise for one second using
   13mm hex socket bit and Impact driver.
                                                                                                               10/ 23

3-9. Replacement of Recoil Starter Rope
DISASSEMBLING                                                               Fig. 21
1) Remove Side handle, and separate Recoil starter assembly from             Recoil starter rope   U-shaped notch
   the machine.
2) If Recoil starter rope is connected with both Starter knob and Reel,
   pull Starter knob to draw the rope out of Starter case and cut it.
   If the rope cannot be cut, pull Starter knob to draw out the rope till
   Reel rotates one turn. Then hook the rope on the U-shaped notch in
   Reel as illustrated in Fig. 21, and turn Reel counterclockwise till         Reel
   Spiral spring is unwound enough.
   CATION: Reel rotates very fast if you release Recoil starter rope
   being pulled. Be very careful not to cut your hands.

3) Unscrew Set screw, and remove Cam and Torsion spring.
4) Remove Reel while pushing Spring case so that it does not get out
   of place. (Fig. 22)                                                      Fig. 22
5) Untie the knots at Starter knob and Reel, then remove worn rope.
                                                                             Spring case




                                                                                                              Reel
                                                                             Push Spring case.




ASSEMBLING                                                                  Fig. 23
1) If Spiral spring has been removed, first put it in place.

2) Put new Recoil starter rope through Starter case. (Fig. 23)
   Note: When using a commercial rope, cut it to 750mm.

3) Tie knots at Reel and Starter knob as illustrated in Fig. 24, 25.
   Do not forget to install Rope stopper as illustrated in Fig. 25
   before tying a knot at Starter knob.
   Important: Rope stopper is not reversible when assembled to
   Starter knob. Be sure to put it through Recoil starter rope as
   illustrated in Fig. 25. Failure to follow this instruction can result
   in broken rope.
                                 Fig. 24                                    Fig. 25



                                                                 Reel
                                                                                                     Rope stopper




                                                                                                     Starter knob
                                                                                                                     11/ 23

3-9. Replacement of Recoil Starter Rope (cont.)
4) Connect Reel with Spiral spring by Fig. 26
   turning clockwise while tilting it
   as illustrated in Fig. 26.            [Start of connecting]
   By rotating Reel clockwise about                            Take care not to Tilt down Reel so that this portion
   half a turn, Reel will move down                            hook this portion can be hooked on Spiral spring.
   to touch Spring case completely,                            on Spiral spring.
   indicating that it has been correctly
   connected with Spiral spring.
   Remember the point at which Reel
   moved down.
   CATION: No force is required to                                                            Lift up this portion
   connect Reel with Spiral spring.                             Spiral spring                 so that it cannot
   Take care not to deform Spiral                                                             touch Spiral spring.
   spring by forcing Reel against
   Spiral spring.
                                            [Correctly connected]                          Put in place without being
                                                                                           caught by Spiral spring




                                                                                                     Hooked on
                                                                                                     Spiral spring


5) Put Torsion spring and Cam in place, and fasten them securely        Fig. 27
   with Set screw. (Fig. 27)
   Important: Reel is not correctly connected with Spiral spring          Torsion spring                        Cam
   if it does not turn smoothly after secure tightening of Set screw.
   Reassemble Reel to Spiral spring as described above in 4).




6) Turn Reel counterclockwise to wind up Recoil starter rope.           Fig. 28
   (Fig. 28)




7) The loose portion can be eliminated from the rope by hooking       Fig. 29
   the rope on the U-shaped notch in Reel, turning Reel clockwise
   two times, then removing the rope from the U-shaped notch.
   (Fig. 29)
   Remark: There are two points at which Reel hooks on Spiral spring.
   Therefore, turn Reel so that it moves down to touch Spring case
   at the same position as it did at first in 4).
                                                                                                               12/ 23

3-9. Replacement of Recoil Starter Rope (cont.)
If Spiral Spring Gets Out of Spring Case
1) Fix the straight end of Spiral spring in the small hole on Spring case      Fig. 30
   as illustrated in Fig. 30.
   Then set Spiral spring in Spring case by winding up clockwise. (Fig. 31)      Spiral spring
2) Spiral spring is factory-lubricated with red grease. However, you may use                             small hole
   Makita grease N No. 2 when repairing. Apply a little amount.



                                                                                                        Spring case


                                                                               Fig. 31




3-10. Disassembling/Assembling Carburetor
REMOVING FROM ENGINE BLOCK                                                     Fig. 32

1) Remove Cleaner case cover.                                                   slotted screwdriver   Choke lever
2) Remove Choke lever by unscrewing PT3x10 Tapping screw using
   slotted screwdriver. (Fig. 32)




3) Remove two M5x45 Pan head screws that fasten Cleaner case and               Fig. 33
   Carburetor. Then remove Cleaner case. (Fig. 33)
                                                                                 M5x45 Pan head screw
   Note: If the pan head screws are left on Cleaner case, Cleaner case
   cannot be removed. Be sure to remove the pan head screws from
   Cleaner case before separating Cleaner case from the engine block.




4) Remove two tubes, then while tilting Carburetor so that it does not touch   Fig. 34
   Throttle wire, separate Carburetor from the engine block. (Fig. 34)
                                                                                Throttle wire




                                                                                                         Carburetor
                                                                                                                          13/ 23

3-10. Disassembling/Assembling Carburetor (cont.)
DISASSEMBLING & CLEANING
                                                           Fig. 35
1) Remove Diaphragm cover and Diaphragm gasket set
   by unscrewing four Pan head screws.                                           Control lever               Spring
   Note: If Gasket is sticking, carefully remove it
   because it is easily broken.
2) Replace Metering diaphragm if it shows any sign of
   wear, wrinkles, curling or tears.                           M3x4 (+) Screw
3) Controller set can be removed by unscrewing
   M3x4 (+) Screw. (Fig. 35)                                                                               Inlet needle
4) Controller set includes Control lever, Inlet needle,                   Hinge pin
   Spring and Hinge pin. When repairing Controller set,
   replace the four parts at a time. (Fig. 35)



5) Before assembling Controller set, be sure to check      Fig. 36
   Inlet needle for wear or deformation. (Fig. 36)
                                                                     [Inlet needle]                        [WRONG]




                                                                                                        Use of worn-down
                                                                                                        Inlet needle will
                                                                                                        result in air pressure
                                                                                                        leakage.

                                                                     GOOD       WORN DOWN



6) When installing Control lever, make sure that the upper end of Spring is correctly placed over the protrusion of
   Control lever. (Fig. 37)
Fig. 37

                    [CORRECT]                                        [WRONG]


                                                                       Control lever


  Metering
  diaphragm
                                    Control lever


                             Inlet needle


                    [WRONG]                                          [WRONG]


                               Dust or debris on the                                             The upper end of Spring
                               valve seat will result in                                         is not placed over the
                               air pressure leakage.                                             protrusion of Control lever.
                                                                                                                         14/ 23

3-10. Disassembling/Assembling Carburetor (cont.)
7) Before removing two Pan head screws, tighten the idling screw on (A) to the full. (Fig. 38)
8) Before installing Strainer, ensure that it is not clogged with dust, dirt or debris. (Fig. 38)
9) Clean up the drainages in Carburetor first by spraying commercial carburetor cleaner and then, several minutes after,
   by washing with gasoline.
Fig. 38
  [Exploded View of Carburetor]
  Throttle holder       O ring 15                                   Controller set


                                                                                                              Pan head screw
                                                                                                                      (4pcs)




                                      Gasket       Pump                       Gasket      Metering  Diaphragm
  Pan head screw     (A)                                                                  diaphragm cover
                                                   diaphragm
  (2pcs)                                                                 Strainer

ASSEMBLING                                                     Fig. 39

1) Referring to Fig. 38, assemble Carburetor.                     Choke adjuster
2) Install (A) so that the choke adjuster is placed on
   the opposite side to the tube ports. (Fig. 39)
                                                                                                               Tube ports




3-11. Testing Air Tightness of Carburetor
Connect Air tightness tester (No.1R127) to the nipple          Fig. 40
(the fuel suction port), and increase the pressure of the
tester up to 0.05Mpa.
Air tightness is normal if the tester keeps on indicating
0.05Mpa about ten seconds. (Fig. 40)


                                                                                                       Air tightness tester
                                                                                                       (1R127)




3-12. Assembling Parts in Handle
1) Hook the longer leg of Torsion spring 11 in the three protrusions on Lock-off lever. (Fig. 41)
2) Hook the other end of Torsion spring 11 on Throttle lever. (Fig. 42)
3) Insert Rod into Throttle lever as illustrated in Fig. 43.
Fig. 41                                  Fig. 42                                       Fig. 43

    Lock-off lever                         Torsion spring 11                                     Rod




    Torsion spring 11                       Throttle lever                                  Throttle lever
                                                                                                                   15/ 23

3-13. Routing Tubes
1) Route Tubes as illustrated in Fig. 44. Fig. 44
2) Install Gasoline filter on the end of
   the fuel suction tube, which will be                                               Tube 3-140
   placed in the fuel tank.                 Primer                                            Tube joint
   Connect Tube 3-140 with the fuel         pump
   suction tube using Tube joint. (Fig. 44)
3) On the top of Housing, route Tubes                                                              Fuel suction tube
    as illustrated in Fig. 45, 46.



                                                                                                       Gasoline filter
                                           Top handle



Fig. 45                                                   Fig. 46
 [Around the fuel tank]                                     [On the top of Housing]
                                                                                               Fuel suction tube
  Place the two tubes             Fuel suction tube          Be sure to place the
  parallel to one another.                                   fuel suction tube
  Ensure that the fuel                                       inside so that it does
  suction tube is placed                                     not touch the hex
  inside.                                                    socket head bolt
  Then insert the tubes                                      which will be very
  into the fuel tank.                                        hot from the heat
                                                             of the engine.


3-14. Removing/Disassembling/Assembling Engine Block
REMOVAL
1) Proceed to disassemble the machine until the following parts are removed; Fig. 47
   Spark plug, Clutch complete, two M4x12 Pan head screws (used for
                                                                              1R170
   fastening Oil pump), Exhaust muffler complete, Starter case complete,
   Ignition coil complete, Flywheel, Carburetor
2) Insert T-type Hex Wrench 3-127 (No. 1R170) from the through hole near
   the hole for the Carburetor fastening screw. And then loosen two M4x14
   Hex socket head bolts that fasten Insulator. (Fig. 47)
3) Remove Damper spring and 4x18 Tapping screw that fastens Top handle to
   Housing complete. (Fig. 48)
4) Release Top handle from Housing by pulling Air duct from the Ignition
   coil installation side. (Fig. 49)
5) Raise the rear end of Top handle by pivoting on the front end, and remove
   two M4x14 Hex socket head bolts that fasten Insulator.
   Be careful not to lose the two bolts. (Fig. 50)
6) Using Impact driver and 1R229 (or 1R171), remove four M5x20 Hex socket head bolts from the top and the bottom of
   the Engine block. Now Engine block can be removed from the left side of Housing.

Fig. 48                             Fig. 49                                Fig. 50



                                                               Air duct




                 Damper spring
                                                                                                                      16/ 23

3-14. Removing/Disassembling/Assembling Engine Block (cont.)
DISASSEMBLING
1) Separate Crank case from Cylinder by removing four M5x20             Fig. 51
   Hex socket head bolts.
   If cannot be separated because of the adhesive, remove by hitting
   the both ends of Crankshaft alternately with plastic or wooden
   hammer. Be careful not to let Crankshaft tilt too much at this time.
   Cylinder can be damaged. (Fig. 51)
   Now you can replace Oil seals on the ends of Crankshaft and two
   Piston rings on Piston.


                                                                                                         Crankshaft

2) Remove Ball bearing 6001 using Bearing Extractor (No. 1R269). (Fig. 52)
   Note: When press-fitting Ball bearing 6001, insert Drill Chuck Remover 11 (No. 1R048) between Crankshaft (R)
   and (L) in order not to deform the bearing. (Fig. 53)
Fig. 52                                          Fig. 53



              Bearing Extractor (No. 1R269)
                                                                                                              1R028

                                                                                                              1R048




                                                     Drill Chuck Remover 11
                                                     (No. 1R048)                                              1R034
                    Ball bearing 6001



3) Pull off Piston clip from Piston pin while turning in the loosening      Fig. 53
   direction using pliers. (Fig. 54)
                                                                                  Piston clip




4) Push Piston pin out of Piston by pushing from the opposite side          Fig. 55
   using T-type Hex Wrench 4-130 (No. 1R171) or the like. (Fig. 55)
5) Now Needle gauge 8 can be extracted from Connecting rod for                             Piston clip
   replacement. When replacing Piston, replace two Piston clip at a time.                                         1R171




                                                                              Piston pin
                                                                                                                       17/ 23

3-14. Removing/Disassembling/Assembling Engine Block (cont.)
ASSEMBLING
1) Assemble Piston so that the triangular marking on Fig. 56
   its top is placed on the exhaust muffler installation
   side (the longer Crankshaft side). (Fig. 56)                    triangular marking



                                                            Crankshaft, longer




2) Piston ring is not reversible when assembled          Fig. 57
   to Piston. Adjusting the end-gap of Piston ring
   fit in the groove of Piston; first the lower Piston                                                   [WRONG]
   ring, then the upper one. (Fig. 57)
   Caution:                                                        [CORRECT]
   1) Because Piston ring is easily broken, take care
       not to expand excessively when installing new        Piston ring       Knock pin
       one.
   2) When inserting Piston into Cylinder, be very
       careful with the position of the end-gap of                                                       [WRONG]
       Piston ring, never placing Piston ring over the
       knock pin. It will result in broken Piston ring
       to force Piston into Cylinder with the ring
       placed over the knock pin.



3) Crankshaft is not reversible when assembled to    Fig. 58
   Cylinder. Place it so that the longer shaft faces
   the Exhaust muffler installation side. (Fig. 58)
4) Apply "Three bond 1215" to the matching surface     matching surface                                  Crankshaft, longer
   between Crankcase and Cylinder; it is enough to     to apply "Three
   apply the adhesive only to the shaded portion of    bond 1215"
   Crankcase.
   And then aligning the protrusion on Crankcase                                                          Exhaust muffler
   with one on Cylinder as illustrated in Fig. 59,                                                        installation side
   assemble them together.
                                                                                                          Cylinder

                                                                                                         Crankcase


                                                         Fig. 59


                                                               Cylinder                                      Crankcase




                                                                          Align these two protrusions.
                                                                                                                      18/ 23

3-15. Disassembling/Assembling Kickback Brake System
DISASSEMBLING                                            Fig. 60                          Fig. 61
1) Release Brake band (Hand guard cover) by                                                Chain slider (R)
   pulling Front hand guard as illustrated in Fig. 60.
2) If Sprocket cover is assembled to the machine,
   separate by loosening Collared hex nut M8 with
   supplied Wrench 13-16.
                                                                             Front
3) Remove Spring cover and Chain slider (R) from                             hand guard
   Sprocket cover Fig. 61.

4) Grasp the rear end of Compression spring 9       Fig. 62
   with Retaining ring pliers ST-2N (No. 1R003),
   and pull it off from Link plate complete.                                                                  1R003
   (Fig. 62)
   Note: Use Retaining ring pliers ST-2N
   (No. 1R003) when grasping or tightening parts
   in the following disassembling/assembling steps.  Link plate
5) Remove Compression spring 6.                      complete                                                 Compression
                                                                                                              spring 9




6) Grasp the Front hand guard section together  Fig. 63
   with Compression spring 9, and pull them off
   from the machine. (Fig. 63)                                                                      Link plate complete
7) When removing Brake band (Hand guard cover),
   unscrew two 4x12 Tapping screws.
                                                           Front guard
                                                           section




ASSEMBLING                                                         Fig. 64
1) Set all parts except Compression spring 9 in place of
   Sprocket cover by doing the reverse of the assembling steps.
2) Grasp the rear end of Compression spring 9 with Retaining
   ring pliers ST-2N (No. 1R003), and then it put through
   Link plate complete while levering up Link plate complete
   as illustrated in Fig. 64.




3) Put Compression spring 9 in Sprocket cover as follows;          Fig. 65
   First, compress one end of the spring with one jaw of the
   pliers put in the first through hole in Link plate complete                   Compress this end.
   other put around the fourth winding of the spring.
   Then push down the other end of the spring. (Fig. 65)
4) Install Spring cover, and fasten Brake band (Hand guard                                                    Push down
   cover) with 4x12 Tapping screws.                                                                           this end.
   Then move Front hand guard to make sure that it works
   properly.
                                                                                       19/ 23

3-16. Miscellaneous Remarks
[1] Do not reuse Gaskets between Exhaust muffler and Cylinder.               Fig. 66
    Always use new one for replacement. (Fig. 66)




[2] If any sawdust or debris in the saw chain tensioner in Sprocket cover,   Fig. 67
    blow it out using power blower or the like. (Fig. 67)




 4. Adjustment
See Instruction manual for adjustment of idling settings and saw chain tension.
                                                                          P 20/ 23

Circuit   diagram



     Color index of lead wires' sheath
      Black
      Red




                                                            Receptacle




                              Body earth                         Switch




                           Insulated connector



                                   Ignition coil complete




                           Insulated receptacle
                                                                                P 21/ 23

Wiring   diagram


   Connect the lead wires (red, black)
   with the terminals of switch before
   assembling the switch to the top
   handle cover.
                                                     Switch

                                     Receptacle




                    Top handle cover

                                                                   Lead wire (red)
                                                                   Lead wire (black)




   Assemble the switch to the top handle cover
   so that the rib on the top handle cover is
   positioned between the terminals of the switch.



                                                          Switch

                               Top handle cover



     Fix the lead wires with
     this lead wire holder.
                                                                              Rib
                                                                                            P 22/ 23

Wiring   diagram



         Route the lead wires through     Lead wires
                                                                    Top handle cover
         the space (the shaded portion)
         between the main housing and
         the top cover.
                                                                    Main housing




                                                                    Top cover




                                                       Lead wires



          Fix the lead wires with
          the lead wire holders.

                                                                         Route the lead wires
                                                                         under the tubes.

                                              Tubes


                                                                      Inside wall
                                            Pins


                                                                         Route the lead wires
                                                                         and the tubes between
                                                                         the pins and the inside
                                                                         wall.


                                                                         Fix the tubes with
                                                                         the lead wire holders.
               Body earth
                                                                                                            P 23/ 23

Wiring   diagram



           Route the lead wire through                       Main housing
           the space (the shaded portion)                                           Lead wire
           between the main housing and
           the baffle plate.


                                                                                     Baffle plate




                                            Route the lead wire
                                            between the pin and
                                            the inside wall.
                                                                         Fix the lead wire with
                                                   Inside wall           the lead wire holder.
                                                        Pin


                                                                                         Route the lead wire
                                                                                         under the tubes.




                                                                                            Tube

                                                                                   Lead wire


                                                                                   Ignition coil complete




                                               Assemble the insulated receptacle
                                               to the ignition coil complete as
                                               illustrated here.



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