Shindaiwa 300 Service Manual
  1. Manuals
  2. Brands
  3. Shindaiwa Manuals
  4. Chainsaw
  5. 300
  6. Service manual

Shindaiwa 300 Service Manual

Hide thumbs Also See for 300:
Table of Contents

Advertisement

Quick Links

$7.50
SERVICE
MANUAL
Shindaiwa
Chain Saws

Advertisement

Table of Contents
loading

Related Manuals for Shindaiwa 300

Summary of Contents for Shindaiwa 300

  • Page 1 $7.50 SERVICE MANUAL Shindaiwa Chain Saws...

  • Page 2: Table Of Contents

    Service Manual Shindaiwa Chain Saws Contents Section page 1 Model Designation and Identification ... 3 2 Troubleshooting ........6 3 Carburetors ..........22 Operation ..........22 Adjustment ..........24 Servicing ..........27 4 Recoil Starters ........40 5 Ignition Systems ........46 Troubleshooting ........
  • Page 3 A statement preceded by the word “ATTENTION” contains information that should be acted upon to avoid damaging the saw. Additional statements that are not preceded by symbols are: IMPORTANT! A statement preceded by “IMPORTANT” is one that possesses special significance. Shindaiwa Inc. 1995...

  • Page 4: Model Designation And Identification

    Model Designation and Identification Section Specifications subject to change without notice. Chain Saws Typical location SHINDAIWA ENGINE MODEL X X X X X SER. X X X X X X X ACC-20 Model 300 Model 300S Model 360 Model 377 Shindaiwa Inc. 1995...
  • Page 5 1 Model Designation and Identification Section Specifications subject to change without notice. Chain Saws Model 488 Model 575 (680 and 695 similar) Model 577P Model 577 57701 Shindaiwa Inc. 1995...
  • Page 6 Model Designation and Identification Section Specifications subject to change without notice. Chain Saws Model 757C Model 757 Model 357 Shindaiwa Inc. 1995...
  • Page 7 3. Ignition As the piston approaches the top of the cylinder, the spark plug fires and ignites the fuel-air mixture. To compensate for increases in engine rpm, spark timing is advanced electronically. Shindaiwa Inc. 1995...
  • Page 8 As the piston exposes the transfer port, exhaust port. crankcase pressure forces fresh mixture into the combustion chamber and helps push the remaining exhaust gasses through the exhaust port. Shindaiwa Inc. 1995...
  • Page 9 To compensate for increases in engine rpm, spark timing is advanced electronically. Combustion and Exhaust and Transfer Compression Ports (closed) Spark Plug CRB-75 Reed Valve Open Low Pressure Figure 2.3 Reed Valve Induction System (reed valve open) Shindaiwa Inc. 1995...
  • Page 10 Exhaust Port (open) Transfer Port (open) Spark Plug CRB-74 Reed Valve Closed Figure 2.4 Reed Valve Induction System (reed valve closed) Shindaiwa Inc. 1995...
  • Page 11 10. Pressure test the carburetor for above? 7. Inspect the impulse tube or pop-off and reseat values. passage for condition and 4. Is the air filter clean and properly operation. Pressure-test crankcase installed? as required. CRB-89 Figure 2.5 Troubleshooting Guide Shindaiwa Inc. 1995...

  • Page 12: Troubleshooting

    CRB-68 ■ Paper-type elements should be cleaned Figure 2.8 Checking Compression with compressed air only. ■ All other Shindaiwa filter elements can be Filter Element; Clean washed in clean fuel mixture and then with fuel mixture blown dry before reinstallation.
  • Page 13 Retainer “starve” the saw. Disconnect the fuel line from the carburetor. Plug or clamp the filter end of the line and use Shindaiwa p/n 99909-93 to pressure test the line for leaks (Figure 2.13). Some early-model Walbro filters IMPORTANT! used an inner element that re- sembled grey wool or felt.
  • Page 14 Test The Impulse Passage, Models 300 through 377 (includes 357) (Figure 2.15) Remove the carburetor and place a small droplet of oil over the impulse passage hole and test as above.
  • Page 15 10. Pop-off and Reseat Pressures (metering valve) (Figure 2.18) 35715 Connect Shindaiwa pressure tester 99909-93 or equivalent to the carburetor fuel inlet, and Figure 2.17 Carburetor Adjustments (357 shown) test the inlet needle assembly for proper pop- off and reseat values.
  • Page 16 Clean or replace arrestor screen Is the exhaust exhaust port is clogged (refer to the Muffler section). system clean with carbon. Inspect and decarbonize exhaust and functioning port (Cylinder and Piston section) properly? (can prevent the engine from firing) Shindaiwa Inc. 1995...
  • Page 17 Improper fuel or fuel Check fuel octane rating. Test for the mixture. presence of alcohol or other oxygenates in the fuel (see Fuels in the Appendix). Carbon deposits in the Decarbonize (see the Cylinder and Piston combustion chamber. section). Shindaiwa Inc. 1995...
  • Page 18 Replace spring, shoes as required speed (Clutch section). Damaged A/V cushion. See Rear Handles and Mounts section. Excessive vibration. Bent crankshaft. See Crankcase section. Damaged flywheel fins. See the Recoil Starters section. Faulty ignition. See the Ignition section. Shindaiwa Inc. 1995...
  • Page 19 Factors Affecting Engine Durability All Shindaiwa products are powered by high 2. Cooling performance engines that produce the most Cooling any high performance engine is a horsepower from the lightest possible complex task.
  • Page 20 (Figure 2.24). Shindaiwa engines require a and has a hammering fuel with an octane rating of at least 87 or effect that can crack or pound a hole through above.
  • Page 21 CRB-89 adjusted too lean Incorrect fuel-oil Fuel filter/tank mixture/wrong type oil/ vent clogged use of highly oxygen- ated fuel (over 10% oxygenate) Leaking or blocked impulse passage or tube Figure 2.25 Common Causes of Engine Seizure Shindaiwa Inc. 1995...
  • Page 22 ■ ■ 22. Carburetor Inlet Screen ..............Clean Dirty ■ 23. Boot/Insulator Block ....................Intact ■ Torn/Cracked ■ ■ 24. Fuel Vent ..................Clear Plugged ■ 25. Crankcase/Cylinder Pressure Check (6 psi) ............. OK ■ Excessive Leakage Shindaiwa Inc. 1995...

  • Page 23: Carburetors

    Air Flow mesh prevents air from passing through the screen in reverse. High Main Jet Pressure and Check Valve Pressure Air Flow pressure opens check valve CRB-71 Figure 3.2 Butterfly Carburetor Shindaiwa Inc. 1995...
  • Page 24 Lever Nozzle Fuel Pressure = Atmospheric Pressure Metering Valve Open Diaphragm Fuel from Pump Inlet Valve Open To Jet or Spring Nozzle Lever Lowered Fuel Pressure CRB-69 Atmospheric pressure Metering moves diaphragm Diaphragm Figure 3.4 Metering Chamber Shindaiwa Inc. 1995...

  • Page 25: Adjustment

    STEP 1. Using a small screwdriver, slowly turn the idle mixture screw clockwise (lean mixture), and note any changes in engine rpm. Turning the idle mixture screw steadily clockwise should cause engine speed to first increase and then decrease as the mixture becomes leaner. Shindaiwa Inc. 1995...
  • Page 26 13,500 ATTENTION! 3000 13,000 2800 11,500 Sustained full throttle no-load operation can cause serious engine damage! Never 3000 13,500 operate any Shindaiwa saw above the 2800 13,500 maximum rpm limits given in the adjacent 2800 12,000 Table. 2800 12,000 2800 12,000 STEP 2.
  • Page 27 3000 rpm ± 100 rpm. Idle Mixture Adjustments (Fig. 3.7) The WYM carburetor used on model 300 and 300S saws uses a single nozzle for both high and low speed operation.
  • Page 28 When a total rebuild is called for, Shindawia recommends: ■ Walbro p/n 57-11 pressure tester (available Metering Lever Gage as Shindaiwa p/n 99909-93), or equivalent. No. 500-13* ■ Walbro tool kit p/n 57-500 (Figure 3.8). ■ A soft-jawed vise, magnifying glass, and access to compressed air.
  • Page 29 Diaphragm Metering Cover Metering Cover ■ HDA diaphragms and gaskets are included in Shindaiwa ■ WT diaphragms and gaskets are included in Repair Kit p/n 22150-81920 Shindaiwa Repair Kit p/n 22128-81100 ■ HDA inlet screen and inlet valve components are ■...
  • Page 30 Throttle and Choke Shafts Figure 3.6 Tabs Failure of shaft-type throttles and choke controls is rare, but can allow air to leak into the carbure- tor. When such wear is noted, Shindaiwa Diaphragm recommends carburetor replacement. ATTENTION! Do not remove choke shaft and throttle...
  • Page 31 Figure 3.17 Idle Progression Holes Main Nozzle Check Valve The main nozzle check valve may be either: ■ A mechanical type (Figure 3.18), ■ A fine-mesh capillary screen (Figure 3.19). CRB-84 Figure 3.18 Mechanical Check Valves Shindaiwa Inc. 1995...
  • Page 32 Figure 3.21 Inspecting the Pump Body Mating Surface. ■ Inspect the metering and fuel pump diaphragms for hardening or cracking. A stiff or wrinkled diaphragm has likely been damaged by gasoline with a high alcohol content, and must be replaced. Shindaiwa Inc. 1995...
  • Page 33 IMPORTANT! Capillary screen valves function by main- taining a thin film of fuel over the screen mesh, allowing fuel to pass through the screen but blocking air from entering the carburetor through the main nozzle. Shindaiwa Inc. 1995...
  • Page 34 Fuel Pump Install the fuel pump gaskets and diaphragm WT Carburetor in the reverse order of disassembly. CRB-80 Figure 3.26 Checking Metering Lever Height Shindaiwa Inc. 1995...
  • Page 35 CRB-97 rod grommet (Figure 3.28). Figure 3.28 Throttle Rod Grommet Orientation For final adjustment of fuel mixture and idle settings, refer to the procedures described on pages 24-25, and 126–127. Shindaiwa Inc. 1995...

  • Page 36: Servicing

    Air Flow and is not otherwise adjustable. CRB-70 Fuel to Nozzle Figure 3.29 WYM Carburetor (Models 300 and 300S) Dissassembly WYM Barrel Idle Idle Speed (Figure 3.31)
  • Page 37 ■ Inspect the throttle lever for wear at the throttle cable hole or at the idle adjustment ramp. Inspect the idle stop screw for damaged threads, and inspect the screw’s plastic head for cracking or other damage. Shindaiwa Inc. 1995...
  • Page 38 Figure 3.35 Metering Valve Installation alcohol content, and must be replaced. ■ Place the individual diaphragms over a lighted flashlight lens or microfiche screen. Replace any diaphragm showing evidence of pinhole leaks or other damage. Shindaiwa Inc. 1995...
  • Page 39 Figure 3.37 Checking Metering Lever Height Screw Low Idle Needle Barrel Valve Carburetor Body Main Jet and O-ring Choke Plate Inlet Screen Fuel Pump Gasket, Plate and Diaphragm Pump Body Metering Gasket, Diaphragm and Cover Figure 3.36 The WYM Carburetor Shindaiwa Inc. 1995...
  • Page 40 Throttle grommets for the choke rod and throttle Choke Grommet control (Figure 3.40). Grommet For final adjustment of fuel mixture and idle settings, refer to the procedures described on page 26. CRB-86 Figure 3.40 Correct Grommet Orientation Shindaiwa Inc. 1995...

  • Page 41: Recoil Starters

    Deflector 488, 575, 577, 680, 695, 757 Rope Guide * Rope guide is not replaceable on Models 575, 680, and 695. Rope and Reel Assembly Housing Cassette-style Spring Assembly Figure 4.1 Recoil Starters Used on Shindaiwa Saws Shindaiwa Inc. 1995...
  • Page 42 Recoil Starters Section Variations by Recoil starters used on Shindaiwa saws can Model be divided into the three basic types shown in Figure 4.1. Although some interchangeability exists between similar starter types, beware of variations in mounting dimensions, cooling intake capacity, or internal specifications.
  • Page 43 REC-59 ■ Lift the starter reel from the recoil housing. Figure 4.3 Removing the Recoil Spring (300–377) Remove the Recoil Spring ■ Models 300, 300S, 360 and 377 Use a Rotor Spring needle-nose pliers to remove the recoil spring from the starter reel. (Figure 4.3) ■...
  • Page 44 If in doubt as to Recoil serviceability, compare with new parts. Housing Lubricate the recoil spring and housing center Lubrication post with a thin film of Shindaiwa Premium Figure 4.6 Rope Guide Installation Gearcase Lubricant. These saw models ...use rope guide Rope Guide...
  • Page 45 Slip Knot IMPORTANT! The reel retaining screw p/n 20035-75170 used on saw models 300 through 377 is precoated with ThreeBond™ liquid screw lock and should always be replaced during starter overhaul. When overhauling starters on saw models 488 through 757, apply ThreeBond™...
  • Page 46 STEP 3. If the starter rope fails to extend or installed and can move freely. On models retract properly as above, repeat the 300 through 377, verify that the recoil previous steps 3-5 to adjust recoil spring ratchet mechanism is extending when the tension accordingly.

  • Page 47: Ignition Systems

    IGN-51 IGN-50 Spark Rotor Switch Charging Coil Coil Rotor Switch IGN-64 IGN-66 Switch Ignition Module IGN-06 Rotor Charging Coil Pulser Coil Spark Coil 488 Spark Coil Location IGN-57 Figure 5.1 Ignition Systems Used on Shindaiwa Chain Saws Shindaiwa Inc. 1995...
  • Page 48 Primary Expanding magnetic field ates as a normally-closed grounding switch Operation:TCI coil that allows current to flow through the mag- Models 300, 300S, Current neto primary windings whenever the moving 360, 357, 377 flow flywheel magnets approach the coil. (Figure 5.2) 1.
  • Page 49 2-3 Spark Coil volt “pulse” of current. 4. The 200-300 volts released from the capacitor now enters the spark coil, and is multiplied into the high- voltage pulse needed to bridge the spark plug gap. Figure 5.3 Operation of the CDI Ignition System (three-piece shown)

  • Page 50: Troubleshooting

    Spark Tester equipment. The following procedures can be used on IGN-24 any Shindaiwa saw. Basic ignition trouble- shooting requires a reliable ohmmeter, an adjustable-gap spark tester (Figure 5.4), and a systematic approach to the problem at hand. IMPORTANT! Jumper Lead Figure 5.4 Essential Tools...
  • Page 51 IMPORTANT! Many ignition problems are caused by nothing more than faulty or corroded wiring or ground connections. Industry-wide, over 50% of all ignition components returned for warranty have nothing wrong with them internally. Shindaiwa Inc. 1995...
  • Page 52 IMPORTANT! A broken or damaged spark plug lead can often be repaired with Shindaiwa Spark Plug Wire Repair Kit p/n 22104-97800 (Figure 5.9). IGN-65 Figure 5.9 Shindaiwa Spark Plug Wire Repair Kit Shindaiwa Inc. 1995...
  • Page 53 ■ Meter reading should be at or near “`” (for (no reading) (no continuity) ‘infinity’) when the test leads are reversed. Further testing of pulser coils is impractical without additional equipment. IGN-72 Ground to Pulser Frame Output Lead Figure 5.11 Testing the Pulser Shindaiwa Inc. 1995...
  • Page 54 If available firing voltage still tests low or reads “0”, test the spark coil output (next page). IGN-52 12 kV or above Figure 5.13 Testing Available Voltage Shindaiwa Inc. 1995...
  • Page 55 Output from analyzer Some analyzers can bench-test a spark coil Test the Spark Output by supplying the 200-300 volt pulses normally Coil Output from coil provided by the CDI exciter coil. If your (2-pc and 3-pc analyzer has this capability, you should be systems;...
  • Page 56 Grounding volts or Lead above between the exciter coil and the engine flywheel. ■ If exciter coil output remains below 125 volts, the exciter is defective and must be replaced. IGN-67 Figure 5.17 Testing Exciter Coil Output Shindaiwa Inc. 1995...
  • Page 57 About 2-3 volts correctly installed on the engine (Figure 5.19). Figure 5.18 Testing Pulser Coil Output CAUTION AIR GAP .05 IGN-56 Arrow Visible Figure 5.19 Correct Pulser Coil Installation Shindaiwa Inc. 1995...
  • Page 58 Coil ■ Using a simulator, the output from a known- good exciter coil can be used to test a spark coil of unknown condition. Jumper Leads Exciter Coil IGN-69 Figure 5.21 Three-piece Coil on a Simulator Shindaiwa Inc. 1995...
  • Page 59 5 Ignition Systems Troubleshooting Section Troubleshooting 300, 300S, 357, 360 and 377 Figures 5.22, 5.23, 1. Is the switch on? Is the switch working 5.24) properly? (The switch should pass current in the OFF position only) 2. Test high voltage output with a gap tester or kV meter.
  • Page 60 8. Test the spark coil for open or shorted windings. Performance-test the coil with a kV meter. 9. Inspect for sheared flywheel key (affects timing only). Figure 5.24 Troubleshooting Three Piece Systems (obsolete) Shindaiwa Inc. 1995...
  • Page 61 Springs Shoe Assembly Bearing Boss “A” Spring Shoe Bearing Assembly Boss “B” Spring Drum Boss “B” Shoes* Springs Sprocket Washer Boss “B” E-ring *Two shoes used on Model 357 Figure 6.3 Clutch Systems Used on Shindaiwa Saws Shindaiwa Inc. 1995...
  • Page 62 STEP 3. Loosen the saw chain (Figure 6.6), and then remove both the saw chain and guide bar. Clutch Shoe Interchange Model Shoe Clutch Drum Assembly p/n Assembly p/n Press Down 300, 300S, 22154-51200 22163-51110* 72320-51200 72320-51110 22154-51200 72326-51100 22160-51200 22160-51501 575, 577, 22155-51200...
  • Page 63 (Figure 6.9). CYL-56 Figure 6.7 Locking the Crankshaft Clockwise CLH-50 to remove Figure 6.8 Removing the Clutch Shoe Assembly Rim Cover Rim Sprocket Drum Drum Bearing Boss “A” Shoe Assembly Springs Boss “B” Figure 6.9 Typical Clutch Assembly Shindaiwa Inc. 1995...

  • Page 64: Clutches

    STEP 6. Using clutch shoe puller tool p/n 22169-96580, rotate the clutch shoe Bearing assembly clockwise to remove (Figure 6.13). Shoe Assembly CLH-06 Figure 6.12 Drum Assembly Clockwise to CLH-63 remove p/n 22169-96580 Figure 6.13 Removing the 757 Clutch Shoe Assembly Shindaiwa Inc. 1995...
  • Page 65 STEP 2. Use a screwdriver to pry clutch boss A from the clutch body as shown CLH-56 (Figure 6.16). Figure 6.15 Exploded View of Shoe Assembly (300-377) STEP 3. Lift the individual clutch shoes and springs from the clutch body (Figure 6.17). Clutch Boss A CLH-51 Figure 6.16 Prying the Boss from the Clutch Body...
  • Page 66 CLH-53 STEP 2. Compare spring length with that of new parts. For hook-type springs used on Models 300, 300S, 360 and 377, inspect for Figure 6.18 Measuring Shoe Wear signs of stretching or other deformation including wear at the hooks.
  • Page 67 STEP 2. Assemble the clutch drum and bearing to the crankshaft in the reverse order of removal. STEP 3. Slide clutch boss “A” (models 300 through 377 only) over the crankshaft. STEP 4. Using hand pressure only, assemble the clutch shoes and spring(s) to clutch boss “B”...
  • Page 68 E-ring verify that the E-ring is fully seated in its slot on the crankshaft CLH-61 Figure 6.25 757 Clutch Assembly Installation Counterclock- wise to Install CLH-71 p/n 22169-96580 Figure 6.26 Tighten the Clutch Hub on the Crankshaft Shindaiwa Inc. 1995...
  • Page 69 WARNING! The saw chain must never rotate at engine idle speeds! STEP 6. Briefly accelerate the engine, and test for proper clutch engagement and disengagement. 57707 Figure 6.28 Proper Chain Tension (slightly tighter for sprocket-nose bars) Shindaiwa Inc. 1995...
  • Page 70 Recommended Idle Speeds a log or wooden block of a diameter equal to about one-half the saw’s guide bar Model length. 300, 300S,360, 377 3000 ■ The saw clutch must engage smoothly 2800 and maintain full engagement throughout the cut.
  • Page 71 Model 357) that engages a matching bore Cylinder Spigot in the crankcase. Flange ■ All Shindaiwa saw models except 300-300S feature a two-ring piston. Gasket ■ The second piston ring allows the engine to develop more power through better sealing,...
  • Page 72 Never attempt to drive a pin from an unsupported piston! Failure to properly support a piston during the above procedure can permanently damage the piston and possibly distort the crankshaft as well! Figure 7.5 Removing the Piston Pin (757 shown) Shindaiwa Inc. 1995...
  • Page 73 Use conventional gasket scrapers only! Sealing surfaces can be easily ruined by incorrect tools or by careless cleaning CYL-51 procedures! Figure 7.8 Removing Baked-on Gasket Material If necessary, stubborn gaskets can be softened with a small quantity of commercial paint remover. Shindaiwa Inc. 1995...
  • Page 74 Cylinders and Pistons Section Inspection Cylinder Bore Shindaiwa hard-chrome plated cylinders cannot be bored for reuse, and oversize pistons are likewise not available. The cylinder bore plating is extremely durable, however, and will often withstand even a total engine seizure.
  • Page 75 Inspect the pin for signs of wear including chipping, fracturing, galling, or discoloration. Use a micrometer to measure pin diameter at both ends and also at the center of the pin, and discard any pin worn beyond the toler- ances given in the Appendix. Shindaiwa Inc. 1995...
  • Page 76 Cylinders and Pistons Section IMPORTANT! Shindaiwa piston pins are heat treated to Piston produce a hardened surface for extended Retainer durability and longer product life. Any pin (press fit) Bearing with visible damage or measurable varia- tion in diameter must be rejected! ■...
  • Page 77 (Figure 7.16). ■ Use pin puller tool p/n 72282-96300 and 300, 300S, 360, 695, 757 377, 357, 488, (no thrust washers) the appropriate push pin to assemble the 575,577, 680 pin to the piston (Figure 7.17)

  • Page 78: Cylinders And Pistons

    Always install a new base gasket. Use no sealants: The cylinder base gasket must be installed dry! STEP 2. Lightly oil both the piston assembly and cylinder bore. CYL-50 Scrap of Wood Figure 7.20 Using a Ring Compressor Shindaiwa Inc. 1995...
  • Page 79 Cylinder Torque operating temperatures. Model Screw p/n in/lbs (Kg/cm) 300, 300S, Torquing 22154-12130 61-70 (70-80) 360, 377 Use an accurate torque wrench to final-tighten 22157-12130 61-70 (70-80) the cylinder base mounting screws to the correct per-model specifications (Figure 7.22).
  • Page 80 ■ Reduce operating temperatures by adjust- STEP 1. Install the carburetor boot (insulator ing the engine’s carburetor settings slightly block on 300-series) and carburetor in the richer than normal. reverse order of removal, and firmly torque ■ Operate the engine at varying speeds and all fastenings.
  • Page 81 8 Engine Crankcase Section Construction Crankcase All Shindaiwa saw crankcases feature diecast Half “C” aluminum alloy construction, producing the (Figure 8.1) lightest possible product with no sacrifice in Crankshaft Assembly strength or durability. Crankcase machining is computer-controlled to extremely close tolerances, allowing crankcase halves to be replaced as individual part numbers.
  • Page 82 STEP 6. Loosen and remove the three/four Allen screws from around the crankshaft. STEP 7. Remove the phillips head screw at the rear of the crankcase (Models 300, 300S, 360, 377, 488 only). See Figure 8.8 CRK-60 and the Table below.
  • Page 83 Never drill through a seal shell! Chips or p/n 22150-96600 other drilling debris may lodge in crank- shaft bearings, leading to early bearing failure. Never allow puller tips or other tools to contact the crankshaft bearings. CRK-54 Figure 8.12 Using a Seal Puller Shindaiwa Inc. 1995...
  • Page 84 12900-62020 02000-06202 02000-06202 Crankshaft bearings (Figure 8.15) Inspection 02030-06202 02030-06203 Inspect both crankshaft bearings for damage or accumulated debris. Shindaiwa engines are high performance engines and require Clogged with Missing premium bearings for maximum performance Debris Components and service life.
  • Page 85 CRK-20 Inspect both threaded ends for signs of stripping, cross- threading, or other damage. Check for damage (chattering, scoring, etc.) at the crankshaft taper. Figure 8.16 Key Crankshaft Inspection Areas Shindaiwa Inc. 1995...

  • Page 86: Engine Crankcase

    (Figure 8.18) IMPORTANT! The crankshafts used on Shindaiwa engines cannot be rebuilt! IGN-60 Figure 8.18 Measuring Runout with a Thickness Gauge...
  • Page 87 Check crankcase half “M” Inspect the seal bores and for scoring in the flywheel especially the machined bearing area. Such damage can bores for distortion or damage. indicate a loose flywheel or distorted crankshaft. Figure 8.19 Crankcase Inspection Areas Shindaiwa Inc. 1995...
  • Page 88 ■ If a bearing must be removed for any Bearing reason, replace it with a new one. Bearing Bore Holder An arbor press can provide a CRK-65 much-improved “feel” during bearing installation. Arbor Press Figure 8.21 Bearing Installation Techniques Shindaiwa Inc. 1995...
  • Page 89 210°F. STEP 2. Install the appropriate crankcase CRK-62 gasket/gasket compound: Use existing stocks Models 300, 300S, 360, 377, 577, 757– of Three-Bond™ Apply a thin bead of Three-Bond™ 1104 until current No. 1207C or 1104 Liquid Gasket to the supply is exhausted.
  • Page 90 Crankcase Bolt Specifications Bolts Part Diameter x Torque Model Used Quantity Number Length in./lbs. (Kg/cm) 300, 300S Crankcase 01020-05300 5 mm x 30 mm 61-70 (70-80) 360, 377 Oil Tank 22910-12480 5 mm x 40 mm Rear 11021-05180 5 mm x 20 mm...
  • Page 91 A-V mounting screws. IMPORTANT: On crankcases equipped with an impulse tube, be sure the tube is correctly oriented and doesn’t become pinched or kinked during assembly. Shindaiwa Inc. 1995...
  • Page 92 STEP 4. Start the saw, and adjust the carbure- tor according to the procedures described in Section 3. IMPORTANT! Following any major overhaul, Shindaiwa recommends a break-in period of approxi- mately 15 to 20 hours. During break-in, adjust carburetor high-speed settings...

  • Page 93: Mufflers

    9 Mufflers Section 300, 300S Gasket Muffler Plate Cover Baffle Cover Stud Body Screen EXH-50 360 AND 377 Gasket Mounting Bolt EXH-51 EXH-55 Cover Screen Cover Mounting Screen Bolts 575, 577, 680 (LATE), 695 Gasket Gasket Locking Tabs Cover Stud...
  • Page 94 ■ Mufflers are bolted to the engine cylinder flange through either a metal or composi- tion gasket. ■ Except for saw Models 300, 300S and 357, all mufflers also feature one or more external mounting lugs. ■ Mufflers used on saw models 357, 360 and...
  • Page 95 9 Mufflers Section Muffler Removal Models 300 and 300S (refer to the exploded STEP 1. Unscrew the two 5 mm muffler cover views on the previous nuts, and then remove the muffler cover. page) STEP 2. Unscrew the two 5 mm muffler stud...
  • Page 96 Never attempt to decarbonize cylinder ports while the cylinder is assembled to the engine! Carbon deposits can become trapped between the piston and cylinder walls, causing severe mechanical dam- age! For cylinder removal procedures, see Section 7. Shindaiwa Inc. 1995...
  • Page 97 For maximum holding power from any thread LocTite™ 272. sealant, Shindaiwa recommends: STEP 4. Torque the muffler support bolts and ■ Thoroughly clean and degrease all bolts and then the two muffler mounting bolts to the...
  • Page 98 USFS and appropriate state/local authorities. Muffler Torque Values Bolt/Thread Torque Model Size* in.lbs (Kgfcm) 300, 300S, 360, 61-70 (70-80) 357, 377, 488 575, 577, 70-79 (80-90) 680, 695 757 (early) 70-79 (80-90) 757 (current)
  • Page 99 10 Chain Brakes Section General Every Shindaiwa saw features a lever-oper- Chain Can Rotate ated chain brake designed to instantly stop all chain rotation whenever the brake is activated. Moving the brake lever forward (away from the operator) allows a powerful spring to tighten a metal band around the saw’s clutch...

  • Page 100: Chain Brakes

    Chain Brakes Section All Shindaiwa Models EXCEPT 357, 377 and 757 (360 shown) Brake is Brake is disengaged activated Spring pulls Spring is band tight compressed Band loose on drum Band tightens around drum CHB-58 Models 357, 377 and 757 (377 shown)
  • Page 101 Block (Figure 10.5) Adjuster Band Adjusting Screw Spring Lever Spring Lever Nut Lever Bolt Inner Lever Band 300, 300S, AND 360 Lever Inner Lever Lever Spring Spring Block Band Band Adjusting Figure 10.5 Chain Brake Components, typical Shindaiwa Inc. 1995...
  • Page 102 ■ Carefully inspect the threads on the lever CHB-56 bolt and band adjustment bolt, and discard Figure 10.8 Releasing Lever Spring Tension (575 shown) either piece if cross-threaded or otherwise damaged. Shindaiwa Inc. 1995...
  • Page 103 STEP 3. Remove the four 4 mm brake assem- bly mounting screws, and then remove the 4 mm x 12 mm single 5 mm mounting screw located above the rear bar bolt (Figure 10.11). CHB-63 Figure 10.11 757 Chain Brake Mounting Locations Shindaiwa Inc. 1995...
  • Page 104 Wash all parts in clean solvent and then wipe or blow dry. Inspection procedures for the 757 brake components are similar to those for other Shindaiwa saws, with the following additions: ■ Be particularly alert for wear, damage or distortion to the metal brake lever, and replace if noted.
  • Page 105 Inertial Operation can be tested by following the procedures described on page 107 of this manual. WARNING! The saw must be OFF during inertial testing! Shindaiwa Inc. 1995...
  • Page 106 35763 STEP 7. If the inner lever, tie strap, or band Bar Nuts are to be replaced, grind and remove the two rivets on the tie strap. Figure 10.19 Model 357 Clutch Cover Removal Shindaiwa Inc. 1995...
  • Page 107 (continued) 357 and 377 brake components are similar to those for the Model 757 and for other Shindaiwa saws, with the following additions: ■ Be particularly alert for wear, damage or distortion to the brake activating lever. If noted, replace the lever.
  • Page 108 The 357, 377, and 757 chain brakes are not adjustable. If either brake fails to engage completely or appears to “drag” while disengaged, the entire assembly must be removed and inspected for worn, damaged, or improperly assembled components. Shindaiwa Inc. 1995...
  • Page 109 11 Oil Pumps Section Operation Spring loading forces the All Shindaiwa saws feature Mikuni™ positive beveled pump shaft displacement oil pumps. See the accompany- against the adjuster. Pump Shaft ing Table for specific applications. The pump is driven by a worm gear at- tached to the saw’s clutch drum, and delivers...
  • Page 110 Replace gear or pump as required ■ Crankcase damage (bar Replace crankcase pad cracked) ■ Oil is wrong type/viscocity Refill with Shindaiwa Premium Bar Oil is leaking and Chain Oil from saw ■ Oil fill cap/gasket is damaged Repair or replace cap as required ■...
  • Page 111 STEP 2. Remove the clutch cover, clutch, clutch drum, pump drive and gear. STEP 3. Remove the oil pump dust cover (Figure 11.6). 57728 Figure 11.5 Extract the Oil Filter Pump Cover RHV-55 Figure 11.6 Removing the Pump Cover (357 shown) Shindaiwa Inc. 1995...

  • Page 112: Oil Pumps

    Tube discard any tube showing evidence of hardening, softening, or other deterioration. Connect a Shindaiwa pressure tester p/n 99909-93 to the inlet (filter) end of the suction tube. Use a tubing clamp or Figure 11.7 Pump and Drive (488 shown)
  • Page 113 STEP 3. Slide the pinion gear against the Models 488, 575, 577, 680, and 695 is re- shaft spring (away from the adjuster shaft), placeable, and is available as Shindaiwa and then withdraw the adjuster shaft and repair kit p/n 99909-89. For gear replacement spring from the pump body.
  • Page 114 STEP 4. Torque the pump cover retaining screws to 20 in/lb. (22 kg/cm). STEP 6. Install a new plastic end cap. IMPORTANT! When installing the oil pump drive gear, apply a light coating of lithium-based grease on the drive gear bore and teeth. Shindaiwa Inc. 1995...

  • Page 115: Rear Handles And A/V Cushions

    Five cushions are used on saw models 300-488, and six cushions are used on all larger saws. To minimize the risk of damaging an A-V...

  • Page 116: Rear Handles And A/V Cushions

    (Figure 12.3). STEP 6. Remove all cushion screws and limiter bolts. Models 300 through 488 are assembled with five A-V cushions. Models 575-757 are assembled with six A-V cushions (see Table on page 114).
  • Page 117 STEP 4. While using care to avoid pinching any tubing or damaging the boot, slide the rear handle completely into the engine crankcase. Shindaiwa Inc. 1995...
  • Page 118 STEP 9. Connect the stop switch, and then reinstall the boot sleeve (where used, Figure 12.7), carburetor, air cleaner, and cylinder cover in the reverse order of removal. STEP 10. Install the bar, chain, and clutch cover in the reverse order of removal. Shindaiwa Inc. 1995...

  • Page 119: Model 357 Top Handle Saw

    As a specialty saw, the 357 looks, feels, and even sounds quite different from any other saw in the Shindaiwa line. Teardown The following sequences are intended as a guide to familiarize you with the general layout (Figure 13.2)
  • Page 120 Clutch Carburetor and Reed Assembly Valve Assembly and Oil Pump Drive Loop Handle Oil Pump and Lines Tank Assembly Powerhead Subassembly Brake Lever Support Ignition Module Recoil Starter Figure 13.1 Major Components of the 357 Top-handle Saw Shindaiwa Inc. 1995...
  • Page 121 STEP 6. Pull the oil suction tube from the oil pump grommet, remove the grommet, and then remove the discharge tube from the bar pad. 35757 Figure 13.6 Remove the Clutch Assembly Shindaiwa Inc. 1995...
  • Page 122 STEP 2. Remove the black plastic inner baffle Spacer Support Arm plate. STEP 3. Use Shindaiwa puller p/n 22150- 96101 to remove the flywheel assembly from the crankshaft (Figure 13.10). STEP 4. Unplug the switch wire from the top of the ignition coil, remove the two 4 mm x 20 mm coil mounting screws, and then remove the coil.
  • Page 123 STEP 2. Remove the screw from the front of the top handle. STEP 3. Remove the E-ring from the cable securing the handle to the rear of the saw (Figure 13.14). Cable and E-ring 5 mm x 12 mm Figure 13.13 Handle Fastener Locations Shindaiwa Inc. 1995...
  • Page 124 STEP 2. Lift the crankshaft from the cylinder end of the crankcase, and then gently pull the piston from the cylinder. Figure 13.16 Removing the Crankshaft Assembly Shindaiwa Inc. 1995...
  • Page 125 Wash all parts in clean solvent and wipe or Reassembly blow dry. Use special care when cleaning mating surfaces, as sealants will not adhere properly to oily surfaces. Reassembly is basically the reverse of teardown, with the following additions or exceptions: Shindaiwa Inc. 1995...
  • Page 126 E-ring is completely seated in its groove. ■ Install the rubber handle grip. If necessary, the grip can be secured with a few drops of contact cement or similar adhesive. IMPORTANT! Be sure to install all handle screws exactly as removed! Shindaiwa Inc. 1995...
  • Page 127 IMPORTANT! (Figure 13.22) the engine is at at idle rpm! Shindaiwa recommends operating any new or rebuilt Shindaiwa saw at light engine Adjust the Low Speed Mixture loads and varying rpms for at least the first (Engine idling, warm) 10–15 hours of operation.
  • Page 128 “stutter” at full throttle. ATTENTION! The high speed mixture screw setting affects both engine performance and durability. Never operate the 357 saw with the high speed mixture screw adjusted to less than 1-1/8 turns! Shindaiwa Inc. 1995...
  • Page 129 23.7 26.0 23.7 23.7 26.0 Fuel tank capacity (cc) Recommended fuel Unleaded 87 octane (300 through 377) Unleaded 89+ octane (488 through 757) Fuel/oil ratio 40:1 with Shindaiwa Premium 2-cycle Engine Oil CLUTCH Material Metal shoe–all models Number of shoes...

  • Page 130: Appendix

    CUTTING ATTACHMENTS Bar mount Oregon A041/K041 (300 through 488) Oregon H009/H005 (550 through 757) Bar stud 8 mm shank/8 mm thread (300 through 488) 9 mm shank/8 mm thread (550 through 757) Bar nut size (mm) Bar length (inches) 14, 16...

  • Page 131: Torque Values

    14 Appendix Torque Values Values given in inch/pounds and (Kg-cm) Section 1 inch/pound = 1.152 Kg-cm 1 Kg-cm = 0.868 in. lbs.) 300, 300S, 360, 575, 680, Location* 377, 488 Engine Crankcase 61-70 (70-80) 70-80 (80-90) 70-80 (80-90) 61-70 (70-80)

  • Page 132: Metric Conversions

    °F to °C = Temperature in F - 32 x 5/9 (.555) °C to °F = Temperature in C x 9/5 (1.8) + 32 Miscellaneous 1 mph = 1.6 km/hr 1 km/hr = .625 mph 1 mpg = .425 km/liter 1 km/liter = 2.35 mpg Shindaiwa Inc. 1995...

  • Page 133: Tolerances And Wear Limits

    Ring/Ring Groove Clearance Standard 0.0015-0.0035 (.04-.09)—All Models Limit 0.0079 (.20)—All Models SHINDAIWA CYLINDERS CAN NOT BE BORED (Replace if deviation is found). Cylinder Inside Diameter use a telescoping gauge and micrometer to measure Standard 1.417 (36) 1.417 (36) 1.457 (37) 1.575 (40)
  • Page 134 Ring/Ring Groove Clearance Standard 0.0015-0.0035 (.04-.09)—All Models Limit 0.0079 (.20)—All Models SHINDAIWA CYLINDERS CAN NOT BE BORED (Replace if deviation is found). Cylinder Inside Diameter use a telescoping gauge and micrometer to measure Standard 1.772 (45) 1.772 (45) 1.772 (45) 1.930 (49)
  • Page 135 For maximum performance and engine life, Old or “stale” gasoline in an engine’s fuel Shindaiwa chain saws require a fuel with an system can attack or deteriorate fuel lines, octane rating of at least 87. carburetor diaphragms, and related fuel system components.

  • Page 136: Fuel And Oil

    ■ If gasoline is to be stored longer than 30 Whenever possible, use only Shindaiwa days, Shindaiwa recommends the used of a Premium 2-Cycle Engine Oil blended at a high-quality fuel stabilizer such as StaBil™...
  • Page 137 ■ 22150-96101 (All models) 22169-96440 Crankcase holder C for above ■ 22169-96430 (757 22169-96410 Crankcase holder M for above Bearing Driver ■ 22154-96430 (300, 300S, 360, 377, 577, Piston Stop (Nylon, all models) ■ 22155-96240 CYL-56 Seal Puller ■ 22150-96600 Fits some models...

  • Page 138: Special Service Tools

    Section CLUTCH TOOLS CHAIN BRAKE SERVICE Clutch Shoe Puller Brake Spring Wrench ■ 22154-96110 (300/300S, 345, 350, 360, 377, 415, 416, 450, 451, 500) ■ 22155-91580 (550, 575, 577, 680, 695) ■ 22150-96510 (488,575, 577, 680, 695) ■ 22169-96580 (757)
  • Page 139 Notes Shindaiwa Inc. 1995...
  • Page 140 Shindaiwa Inc. 11975 SW Herman Road P.O. Box 1090 Tualatin, OR 97062 Phone 503 692-3070 1995 Shindaiwa Inc. Form No. 60654 Printed in U.S.A. FAX 503 692-6696 Shindaiwa is a registered trademark of Shindaiwa Inc. Specifications subject to change without notice.

This manual is also suitable for:

300s575377360488680 ... Show all

Table of Contents