General recommendations Keep this in mind: Special tools Some work procedures in this Workshop Manual require the Do not start the engine unless the clutch and clutch drum use of special tools. In each section where this is appropriate are fitted. the tool and order number are illustrated.
Starter unit Contents Dismantling of the starter unit ..........4 Replacing the starter cord without dismantling the pulley ... 5 Dismantling ................7 Assembly ................8...
Starter unit WARNING! When working on the starter unit wear protective glasses to avoid eye injuries in the event that the return spring flies out. Dismantling of the Dismantling of the starter unit starter unit Mod. 650, 700 Mod. 650, 700 Dismantle the air filter cover, intermediate Untighten the screws for the air filter wall and cylinder cover.
Starter unit Allow the pulley to slowly rotate back- Allow the pulley to slowly rotate back- wards. wards. Remove the starter handle. NOTE! Brake the rotation with the thumb. Untie the knot on the starter rope and remove the starter handle. Tips! The knot may be difficult to untie.
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Starter unit Anchor the starter rope in the starter Insert the rope through the rope guide in handle with a double knot. the starter housing and anchor it in the starter handle with a double knot. Tension the return spring. Tension the return spring.
Starter unit Dismantling Dismantling Mod. 650, 700, 950 Mod. 650, 700, 950 Remove the screw in the centre of the Remove the screw in the centre of the pulley and lift off the pulley. pulley. Lift off the pulley. Dismantle the spring cassette. Remove the screws and lift off the spring cassette.
Starter unit Assembly Assembly Mod. 650, 700, 950 Mod. 650, 700, 950 Clean the starter unit components and fit Clean the different starter unit parts. the spring cassette. Lubricate the return spring with oil and place the spring cassette in the starter unit housing.
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Starter unit Tension the return spring. Tension the return spring. Check that the spring tension is completely 1. Check that spring tension is competely released, and lift the starter cord up into released. the cut-out in the pulley. 2. Lift the starter cord up into the cut-out in the pulley.
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Anchor the starter cord in the starter Enter the cord through the cord guide in handle with a double knot. the starter unit and anchor it in the starter handle with a double knot. Fit the starter unit and other parts in the Fit the starter unit.
Ignition system Contents The principle of the ignition system ......12 Checking the ignition spark ........13 Replacing the spark plug protection ......15 Dismantling ..............15 Starter pawls ............... 17 Assembly ..............17...
Ignition system NOTE! The engine is fitted with an electronic ignition sys- tem consisting of flywheel, ignition coil and trigger During all test running of the cutting saw the unit. clutch and clutch cover must be fitted before the engine is started! The ignition system has no moving parts.
Ignition system Checking ignition spark Checking ignition spark Clean the electrodes and check the Dismantle the plug and clean it from soot by means of a wire brush. electrode gap. Check the electrode gap. It should be 0.5 mm (.020 in). Adjust the gap to the correct distance with the side electrode.
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Ignition system Check the ignition cable’s connections. Still no spark? Check the plug connection. Pull off the rubber protection at the plug (A) and ignition module (B) and check that the ignition cable is undamaged. If necessary cut off a piece of the cable to ensure good contact.
Ignition system Adjust the air gap. Adjust where appropriate the air gap to the correct distance. • Release the screws holding the ignition module. • Position the feeler gauge on the magnets of the flywheel and press the ignition module against flywheel. •...
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Ignition system Fit piston stop No. 502 54 15-01 in the Insert piston stop No. 502 54 15-01 in the spark plug hole. sparking plug hole. Make sure that the piston stop does not come out through the exhaust port, it must rest against the front of the cylinder wall when the piston approaches Top Dead Centre.
Ignition system Tips! Tips! Tap the flywheel puller screw sharply with The flywheel may sit very tightly on the a hammer if the flywheel sits tight. shaft. To simplify dismantling - tap the flywheel pullers screw sharply a few times. Hold the engine in the air with the handle on the flywheel puller.
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Ignition system Fit the ignition module. Fit the ignition module. Adjust the air gap (0.3 –0.5 mm/0.012– Adjust the air gap to the correct size (0.3 –0.5 mm/0.012–0.020"). 0.020"). See also page 14–15. Fit the other cables. Fit the other cables and make sure that Fit the other parts in the reverse order to dismantling.
Air dry the filter and soak it in air filter oil and squeeze out Soak it in air filter oil (Partner) and squeeze the excess before refitting. out the excess before refitting. If the filter is damaged it should be replaced...
Fuel system When the filter and covers are fitted it is K650/700 very important to make sure that all the seals are undamaged and correctly positioned. Seals which do not seal properly result in less efficient centrifugal cleaning and ra- pid blockage of the air filter.
Fuel system Fuel filter Fuel filter Mod. 650, 700 Mod. 650, 700 On the fuel pipe in the tank there is a fuel The fuel filter can be taken out through filter. This is accessible through the filler the tank's filler hole. hole.
Fuel system Carburettor Carburettor Dismantling, all models Dismantling, all models Dismantle all covers and air filters so that Dismantle all covers and air filters so that the carburettor becomes accessible. the carburettor becomes accessible. Blow clean the carburettor chamber with Close the choke flap to prevent dirt pene- trating into the engine.
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Fuel system Dismantle the screw (A) and then the two Remove the screw (A) and then the two carburettor screws. carburettor screws. Lift off the carburettor. Insert key 502 50 18-01 through the hole in the crankcase and tank part. Lift off the carburettor together with the air filter connection and throttle lever.
Fuel system Carburettor design Carburettor design The carburettor can be divided into three The carburettor can be divided into three different functional units: the metering different functional units: the metering section, mixing section, and pumping section, mixing section, and pumping section.
Fuel system Speed limiter Mod. 650, 700 A speed limiter is fitted on the side of the carburettor housing. The speed limiter is fixed with Loctite and should not be released during servicing of the carburettor. When the engine speed is less than 9,200 rpm the ball seals the extra fuel channel (A). The pressure of the spring presses the ball against the seat with a precise proven pressure.
Fuel system Combinations of carburettors, induction pipe, seals, screwdriver guides K650 Active, K700 Active Carburettor Induct. pipe Seal Insert, seal Screwdriver guide HS175E 503 28 03-20 506 21 41-01 506 22 65-01 Black Not compensated Black Rubber foam, bonded to cyl. housing K650 Active II, K700 Active II Carburettor Induct.
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Fuel system In the event of leakage - dismantle the In the event of leakage dismantle the needle valve. needle valve. Release the screw and lift off the lever, shaft, needle valve and spring. Check the needle valve and lever for Check the needle valve for damage at the wear.
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Fuel system Unscrew the nozzle needles. Unscrew the nozzle needles. NOTE! Notice the two types of needles and how they are positioned (e.g. the H-needle is slightly shorter than the L-needle). On EPA models which have fixed nozzles, the nozzles can be cleaned or changed once the seal plugs have been removed.
Fuel system Assembly of the Assembly of the carburettor carburettor Blow clean the carburettor housing. Blow clean the carburettor housing. Fit a new welch plug. Fit a new welch plug. Fit a new main jet nozzle. Use a suitable mandrel to achieve com- plete tightness.
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Fuel system Check that the carburettor is tight. Connect pressure tester No. 501 56 27-01 to the fuel inlet in the No leakage is permissible at 50 kPa carburettor. pressure. Pump up to 50 kPa pressure. Submerge the carburettor in a jar with petrol to simplify inspection for leakage.
Fuel system Mod. 1250 The carburettor on this model is of Walbro Walbro WG 9 manufacture. The service method is the same as for the Tillotson carburettor. Note the small O- ring (A) placed on the compensation device. This carburettor does not have a speed limiter either.
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Fuel system The adjustment of the carburettor may vary somewhat depending on the humidity, temperature and air pressure. L = Low speed nozzle H = High speed nozzle T = Adjuster screw for idling ● With the L and H nozzles the fuel volume is adjusted to the air flow which the opening of the throttle control permits.
Fuel system Fine adjustment of the idling screw (T) Adjust the idling speed with the adjuster screw (T). The idling speed should be adjusted after the high and low speed nozzles have been adjusted. If it is necessary to adjust the idling screw turn the screw (T) first clockwise until the cutting disc begins to rotate, and then anti-clockwise until the cutting disc stops rotating.
Fuel system Mod. 1250 Mod. 1250 Separate the tank unit and crankcase. Separate the tank unit and crankcase just enough to gain access to the tank vent. Put a screwdriver between the fueltank Prise away the non-return valve with a and the non-return valve.
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Fuel system Lift off the half of the grip and the throttle Lift off the half of the grip. control. NOTE! Note the washer under the throttle control and the sleeve inside the control. One end of the return spring for the throttle control catch goes in the hole on the throttle control.
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Fuel system Fix the spacer washer with a little grease 8. Place the spacer washer in position on the right-hand grip half. on the right-hand grip. Fix it with a little grease. Hook the throttle lever in the throttle control and place the grip half in position.
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Fuel system Mod. 1250 Mod. 1250 Separate the tank unit and crankcase, Separate the tank unit and crankcase. and press off the three bearing pins. (Where appropriate see chapter on vi- bration damper.) Press off the three bearing pins with a suitable punch (Ø...
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Fuel system Fit the throttle control and safety catch in 1. Push the throttle control with attached the reverse order to dismantling. throttle wire into the rear grip. Check that the spring on the catch goes 2. Enter the back edge of the safety into the hole in the throttle control.
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Centrifugal clutch The centrifugal clutch has the purpose of but also in the reverse case if the cutting equipment transferring the power between the engine and should stick. This avoids irregular load alternations the cutting equipment. As the name implies it on the crankshaft.
Centrifugal clutch Place an object which is approx. 5.5 mm Place an object (e.g. a nut) which is (0.22") thick between the clutch shoe and approx. 5.5 mm (0.22") thick between the the spoke. clutch shoe and the spoke on the clutch hub on the back of the clutch.
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Centrifugal clutch Mod. 950, 1250 Mod. 950, 1250 Dismantle all the cutting equipment and Dismantle the front and rear belt covers, unscrew the plug. cutter arm with cutter disc and drive belt. Fit piston stop No. 502 54 15-01 and Remove the air filter covers and air filter, dismantle the clutch clockwise.
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Centrifugal clutch Assembly Assembly Mod. 650, 700 Mod. 650, 700 Press in the new needle bearing until it is Press in the new needle bearing with a flush with the outer edge of the clutch vice and a suitable sleeve until it is flush drum’s hub.
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Centrifugal clutch The clutch drum’s bearing is lubricated The clutch drum’s bearing is lubricated automatically with the oil in the fuel mixture automatically with the oil in the fuel which is pressed out through the channel mixture. in the crankshaft. When the piston moves down in the cylin- der the fuel mixture in the crankcase is compressed.
Cylinder and piston During service work on these components clean- The cylinder and piston are two of the components liness is of extreme importance. It is therefore which are exposed to the greatest tensions in the recommended that the cylinder and the area aro- engine.
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Cylinder and piston Mod. 950 Mod. 950 Dismantle all components so that the Dismantle all components so that the cylinder becomes accessible. cylinder becomes accessible. Remove the start valve, blue centrifugal Dismantle the carburettor and screws nozzle and muffler. that hold the spacing piece to the crank- case.
Cylinder and piston Unscrew the cylinder screws and lift off Unscrew the cylinder screws with key No. the cylinder. 502 50 57-01 (3/16”) and lift the cylinder at an angle forwards/upwards Dismantle the spacing piece from the cylinder. Place a clean cloth in the crankcase opening to prevent dirt from dropping down into the crankcase.
Mixing ratio: 1:50 (2 %). Powerful scratches along the full piston If Partner two-stroke oil is not available another high quality two-stroke oil can be used. skirt on the exhaust side Mixing ratio: 1:33 (3 %) or 1:25 (4 %).
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Cylinder and piston Piston seizures resulting from severe carbon deposits Excessive carbon deposits can result in damage similar to that caused by insufficient lubrication. The piston skirt, however, is darker in colour as a result of the hot combustion gases which are pressed past the piston ring. This type of piston damage begins at the exhaust port where carbon deposits can loosen and stick between the piston and cylinder wall.
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Cylinder and piston The guide pin for the piston ring has been pres- Irregular grooves on the piston's inlet side caused Deep and irregular grooves caused by a loose sed up through the piston head. by a broken bearing cage. circlip.
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Cylinder and piston Reasons: Procedure: ● Defective air filter. Small dust particles Fit a fine-mesh filter. pass through the filter. ● The filter is worn out as a result of Check the filter carefully for holes and overcleaning, whereby small holes damage each time it is cleaned.
Cylinder and piston Service tips Defect: Procedure: Broken cooling fins, damaged threads or broken screw at In severe cases - replace the cylinder. exhaust port. Repair the thread with Heli-Coil. Seizure marks in the cylinder bore (especially at the exhaust Rub the damaged part with fine emery cloth to remove port).
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Cylinder and piston Fit a new cylinder base gasket. Carefully scrape off old gasket residue from the cylinder and cylinder base sur- face on the crankcase. Place a new gasket in position on the crankcase. Gasket paste is recommended! Lubricate the cylinder bore with a few Lubricate the cylinder bore with a few drops of oil and push down the cylinder drops of oil and push down the cylinder...
Cylinder and piston Mod. 1250 Mod. 1250 Fit the cylinder and piston in the same Follow the instructions for ”Cleaning, way as described above. inspection”, ”Assembly” and ”Decom- pression valve” before fitting the piston cylinder. NOTE! Fit the spacing piece and throttle wire guide on the cylinder before fitting it on the crankcase.
Cylinder and piston Check that the outlet hole in the valve is Check that the outlet hole in the valve is open, in similarity with the hole in the open, in similarity with the hole in the cylinder wall. cylinder wall. Clean if necessary.
Crankshaft and crankcase Contents Replacing the seal on flywheel side ...... 60 Replacing the seal on clutch side ......61 Vibration dampers ..........62 Dismantling, assembly ........... 66 Repair bushing ............69 Inspection of crankshaft ........71 Pressure test ............72...
Crankshaft and crankcase The purpose of the crankshaft in the engine is to The crankshaft is housed in the crankcase with heavy-duty ball bearings. In addition to acting as convert the forward and return strokes of the piston to rotation. A stable construction is required to the bearing point for the crankshaft, the crankcase accomplish this in order to withstand high pressure, also functions as scavenging pump for the fuel/air...
Crankshaft and crankcase Lubricate the shaft with engine oil and fit Lubricate the shaft with engine oil and put a new seal. a new seal in place with the plate cover facing outwards. Press the seal in the crankcase with a suitable drift until it lies flush with crankcase.
Crankshaft and crankcase Mod. 950 Mod. 950 Pull off the seal with an extractor. Dismantle all parts on the clutch side so that the seal becomes accessible. Screw in the seal extractor as far as it goes in the seal, and pull off the seal. 502 50 55-01 Lubricate the shaft with a few drops of oil Lubricate the shaft with a few drops of oil...
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Crankshaft and crankcase Remove the vibration damper by the rear In order to dismantle the vibration dam- handle by removing screws (A) and one per in the rear handle the screws (A) must half of the handle (B). be dismantled and the handle half (B) removed.
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Crankshaft and crankcase Remove the screws which hold the grip to 4. Remove the screws which hold the the tank unit, and the screw which holds grip to the tank unit. the vibration damper. 5. Remove the screw which holds the Separate the tank unit and crankcase, vibration damper.
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Crankshaft and crankcase Mod. 1250 Mod. 1250 Vibration damper at cylinder Vibration damper at cylinder Remove the screws (A) and (B). 1. Remove the screw (A) which holds the damper to the grip. 2. Remove the screws (B) which hold the grip to the tank unit.
Crankshaft and crankcase Mod. 1250 Mod. 1250 Rear vibration damper Rear vibration damper 1. Dismantle the starter unit. Dismantle the starter unit and the two screws which hold the rear, upper vibra- 2. Remove the two screws which hold tion dampers. the rear, upper vibration dampers.
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Crankshaft and crankcase Remove the screws (B). Remove the screws (B). Lift off the crankcase. Lift off the crankcase. 505 38 13-08 Remove all the screws (7 pcs) which hold Remove all crankcase screws. the crankcase halves together. 505 38 13-08 Separate the crankcase halves.
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Crankshaft and crankcase Heat up the crankcase halves to 150° – Heat up the crankcase halves to 150° – 200° C. 200° C with a hot air gun. Dismantle the ball bearings. Tap the crankcase half against a block of wood so that the ball bearing drops out.
Crankshaft and crankcase Push the crankcase halves together and Place the clutch side’s crankcase half tighten the crankcase screws. over the crankshaft. Position the crankcase screws to prevent the gasket from sliding out of position. Push the crankcase halves together with tool 502 50 30-10.
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Crankshaft and crankcase Pull the repair bushing into place with an M5 screw and washer as shown in theillustration. M5 x 20 mm NOTE! Align the bushing correctly, so that the chamfered section faces the cylinder plane. 503 27 35-99 Mod.
Crankshaft and crankcase Remove all screws which hold the crank- Remove all screws (9 items) which hold case halves together. the two crankcase halves together. Separate and assemble the crankcase Separate and assemble the crankcase halves in the same way as described for halves in the same way as described for mod.
Crankshaft and crankcase Check the big end bearing. Check the big end bearing. There should be no radial play (upwards and down- wards) on the connecting rod. It should, however, have an axial play to ensure good lubrication of the big end bearing.
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Crankshaft and crankcase Models 650, 700 – Carburettor side Remove the carburettor from the cylinder. Fix cover washer No. 506 34 45-01 to the cylinder with an M5x15 screw. 506 34 45-01 Models 650, 700 – Crankcase lubrication hole Remove the centrifugal clutch and seal the lubrication hole with tape. Model 950 –...
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Model 950 – Crankcase lubrication hole Remove the centrifugal clutch and seal the lubrication hole with tape. Model 1250 – Muffler side Remove all the cutting equipment, including the rear cutting arm. Remove the muffler and heat shield plate. Install cover washer No. 502 71 39-01 over the exhaust port. Use the muffler attachment screws and nuts, together with two spacer sleeves No.
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Model 1250 – Crankcase lubrication hole Remove the centrifugal clutch and seal the lubrication hole in the crankshaft with tape.
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Rectify all faults as soon as they are discovered in belt. For this reason when changing the belt order not to compromise user safety always use a Partner Genuine Belt, which is Dismantling Dismantling Mod. 650, 700 Mod.
Cutting equipment Release the belt tension and dismantle Unscrew the nuts (A). the front belt guard and cutter arm. Screw out the tensioning screw (B) so that the belt tension releases. Remove the belt guard and cutter arm. Dismantle the clutch cover and drive belt. Remove the nuts (C) and screw (D).
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Cutting equipment Remove spacer sleeve (A), the screws, Remove spacer sleeve (A), the screws, plastic cover, cover washer, plastic was- plastic cover, cover washer, plastic was- her, rubber washer and a further plastic her, rubber washer and a further plastic washer.
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Cutting equipment Turn the guard while the other parts are held in place. Then install a plastic washer (C), the thin rubber washer (D), plastic washer (E), cover plate (F) and plastic cover (G). Tighten the three screws and check that the guard can be turned.
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Fig. E. Worn off strips of belt, worn reinforcement, resulting from poor contact, oil on the pulley, or incorrect belt quality. Use Partner Genuine Belts. Place a new drive belt round the clutch Place a new drive belt round the clutch drum and it the clutch cover.
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Cutting equipment Lift the cutter arm in position and fit the Lift the cutter arm in position. Place the front guard and belt tensioning device in front belt guard and belt tensioning device. position. Tension the drive belt and tighten the nuts.
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Cutting equipment Fit the cutter arm Lift the cutter arm in place. Tension as the drive belt at the same time Fit the drive belt over the front pulley. as the cutting disc is rotated, and tighten Push the front belt cover in place and the two nuts.