Echo CS-2510TES Service Manual
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Echo CS-2510TES Service Manual

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CS-2510TES
ECHO:
250Ts 250TCs
shindaiwa:
(Serial number: 37000001 and after)
Ref. No. 401-39

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Summary of Contents for Echo CS-2510TES

  • Page 1 CS-2510TES ECHO: 250Ts 250TCs shindaiwa: (Serial number: 37000001 and after) Ref. No. 401-39...
  • Page 2 INTRODUCTION This service manual contains information for ser- vice and maintenance of ECHO CHAIN SAW, model CS-2510TES, shindaiwa CHAIN SAW, model 250Ts and 250TCs For systematic diagnosis, to avoid extra work, time loss and to meet Emission regulation, please refer to “Troubleshooting guide” that describes problems, testing, remedies and references.

  • Page 3: Table Of Contents

    CS-2510TES 250Ts, 250TCs TABLE OF CONTENTS Page Page 1 SERVICE INFORMATION ........2 5 CLUTCH SYSTEM ..........41 Specifi cations ...........2 Inspecting clutch parts ........41 Technical data ..........3 Replacing clutch parts ........43 Torque limits .............4 Installing clutch assembly .......43 Special repairing materials .......4 Service limits ............5...

  • Page 4: Service Information

    35.0 (1.378) Stroke mm(in) 26.0 (1.024) Compression ratio Carburetor Type Diaphragm horizontal-draught with separated primer Walbro WT-1153 (CS-2510TES) Model WT-1155 (250TS, 250TCS) with Large D-shaped mixture needles Venturi size-Throttle bore mm(in) 11.11-14.3 (0.437-0.563) CDI (Capacitor discharge ignition) system Ignition...

  • Page 5: Technical Data

    CS-2510TES 250Ts, 250TCs SERVICE INFORMATION Cutting devices Sprocket nose bar Carving Guide bar Type C20S91-35SA C25S91-40SL C30S91-47ML C20H25-52CL C25H25-60CL Called length Gauge 0.050 Saw chain Carlton N1C-BL Type OREGON 25AP OREGON 91PX Number of drive links Pitch Gauge 0.050 1-2 Technical data...

  • Page 6: Torque Limits

    Ignition coil Loctite #222, ThreeBond #1344J or equivalent Ignition switch Loctite #242, ThreeBond #1324N or equivalent Grease Recoil starter Needle bearing, clutch Lithium based grease or ECHO XTended Worm gear Protection Lubricant Auto-oiler Oil seal lip Chain brake (metal contact part)

  • Page 7: Service Limits

    CS-2510TES 250Ts, 250TCs SERVICE INFORMATION 1-5 Service limits Description mm (in) A Cylinder bore When plating is worn and aluminium can be seen Piston outer diameter Min. 34. 92 (1.375) Piston pin bore Max. 8. 035 (0.3163) Piston ring groove Max.

  • Page 8: Special Tools

    CS-2510TES 250Ts, 250TCs SERVICE INFORMATION 1-6 Special tools Part Number Description Reference G310-000050 Tachometer PET-304 Measuring engine speed Y089-000094 Carb. tool KIT Adjusting carburetor X645-000031 D-shaped tool (L) Adjusting D -shaped L / H mixture needle X603-000050 Driver(2.5mm) Adjusting throttlle adjust screw...

  • Page 9: Starter System

    CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2 STARTER SYSTEM (ES-start / S-start) (A) Starter case (B) Fan cover (C) Rewind spring (D) Rewind spring case (E) Rope reel (F) Power spring (G) Pawl catcher (H) Screw (J) Starter rope (K) Starter grip...

  • Page 10: Disassembling Starter Assembly

    CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2-1 Disassembling starter assembly 1. Remove three bolts and remove starter assem- bly (A) from unit. 2. Remove fan cover (B) from starter assembly (A). 3. Pull out starter rope about 30cm (12in) and hold rope reel (C) by hand.

  • Page 11: Replacing Starter Rope

    CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2-2 Replacing starter rope 1. Pull out and untie knot (A). 2. Pull knot (B) to remove rope from rope reel (C). 3. When installing a new starter rope, singe both ends of the rope to prevent fraying.

  • Page 12: Assembling Starter

    CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2-3 Assembling starter 1. If rewind spring (A) is unwound from rewind spring case (B), wind the spring (A) inside case (B) as shown. NOTE : Apply small amount of lithium based grease to rewind spring case (B), before wind the spring.
  • Page 13 CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2-3 Assembling starter (Continued) 6. Check for proper engagement of rewind spring and rope reel (F) by turning rope reel (F) clockwise and counterclockwise. 7. Apply small amount of lithium based grease to power spring mounting groove (f3) of the rope reel (F).

  • Page 14: Replacing Starter Pawl

    CS-2510TES 250Ts, 250TCs STARTER SYSTEM 2-3 Assembling starter (continued) 13. Pull out starter rope all the way, and check that rope reel (F) can be rotated an additional half or more turn clockwise as shown, to prevent rewind spring from breaking.

  • Page 15: Ignition System

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3 IGNITION SYSTEM (A) Ignition switch (B) Spark plug (C) Spark plug cap coil (D) Spark plug cap (E) Ignition coil (F) Bolt (M4) (G) Collar (H) Flywheel (J) Nut (M8) (K) Woodruff key...

  • Page 16: Troubleshooting Guide

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-1 Troubleshooting guide Start Remedy Inspect S.T. Pole shoe air Adjust pole shoe air gaps. gaps Clean / Regap / Spark plug S.T. Replace. S.T. Flywheel Replace flywheel. magnet Spark Replace. S.T. plug cap/ coil...

  • Page 17: Testing Spark

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-2 Testing spark 1. Unhook ring (A) with screwdriver (B) or equiva- lent and open cap cover (C). 2. Remove spark plug cap (D) from spark plug (E). 3. Connect spark plug cap (D) to spark tester 897800-79931 (F), and connect spark tester lead (G) on spark plug (E) as shown.

  • Page 18: Inspecting Spark Plug

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-3 Inspecting spark plug 1. Remove spark plug to inspect for fouling, cracked or broken insulator, cracked outer elec- trode, or rounded center electrode. Clean or replace spark plug as required. 2. Set spark plug gap (A) by bending outer elec- trode (B).

  • Page 19: Inspecting Ignition Switch

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-5 Inspecting ignition switch 1. Remove starter assembly from unit. 2. Connect one probe of Ohm-meter or multi-meter to ignition switch terminal (A). Connect the other probe to another ignition switch terminal (B). 3. When ignition switch is “RUN” position, tester should indicate infi...
  • Page 20 CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-6 Replacing ignition switch (Continued) 4. Loosen nut (F) and remove sprocket guard (G). 5. Remove bolt (H), chain catcher (J), and sprocket guard plate (K) 6. Remove bolt (L) and brake lever (M). 7. Remove plug (N) and bolt (P).
  • Page 21 CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-6 Replacing ignition switch (Continued) 9. Remove ignition switch (S) . t1, t2 {Installing} 10. Install new ignition switch (S), passing switch lead (t1) and (t2) through notch on rib (U1), (U2) and (U3) .
  • Page 22 CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-6 Replacing ignition switch (Continued) 15. Pass switch lead (t1) and (t2) under fuel lines t1, t2 (W). 16. Install bolt (A) with ignition switch terminal (B) and connect ignition switch (C) as shown (Refer to “3-7 Replacing ignition coil”, “3-8 Setting pole shoe...
  • Page 23 CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-6 Replacing ignition switch (Continued) 22. Insert front / starter side tab (e2) on dust cover into engine cover. 23. Insert rear / clutch side tab (e3) on dust cover into engine cover. 24. Insert front / clutch side tab (e4) on dust cover into engine cover with screwdriver or equivalent.

  • Page 24: Replacing Ignition Coil

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-7 Replacing ignition coil 1. Remove starter assembly. 2. Unhook ring (A) with screwdriver (B) or equiva- lent and open cap cover (C). 3. Disconnect spark plug cap from spark plug. 4. Loosen two bolts (D) and remove ignition switch terminal (E), ignition coil (F), taking care not to lose collars.

  • Page 25: Setting Pole Shoe Air Gaps

    CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-8 Setting pole shoe air gaps     1. Loosen two bolts (A) and insert Module air gap gauge: 91004 (B) or 0.3 - 0.4 mm (0.012 - 0.016 in) thick feeler gauge between fl ywheel (C) and ig- nition coil shoes (D).
  • Page 26 CS-2510TES 250Ts, 250TCs IGNITION SYSTEM 3-9 Inspecting fl yweel and woodruff key (Continued) 6. Remove starter pawls. Then set puller Y089- 000110 or Y089-000111 (G) on flywheel (A) as shown. 7. Tighten two nuts (g1) on the puller alternately to remove fl...

  • Page 27: Fuel System

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4 FUEL SYSTEM (K2) (K1) (R2) (K3) (R1) (T) (U) (A) Air cleaner cover (N) Joint (black) (B) Air fi lter (P) Purge line (L-shaped) (C) Fuel cap (Q) Purge bulb (D) Gasket (R1)Fuel return line (3x5x58mm)

  • Page 28: Inspecting Air Fi Lter

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-1 Inspecting air fi lter 1. Close choke shutter. 2. Turn lifting hook (A) down to the end. 3. Unlatch air cleaner cover latch (B) with screw driver (C) or equivalent. 4. Turn up and remove air cleaner cover (D).

  • Page 29: Inspecting Fuel Cap And Fuel Strainer

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-2 Inspecting fuel cap and fuel strainer 1. Remove fuel cap. 2. Inspect fuel cap for cracks and gasket (A) for cuts or damage, and replace with new one as re- quired. 3. Replace connector (B) if damaged.

  • Page 30: Inspecting Fuel Tank And Line

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-3 Inspecting fuel tank and line 1. Clean fuel tank inside as required. 2. Insert screwdriver (A) or equivalent between dust cover (B) and engine cover, and pry dust cov- er (B) away from engine cover.

  • Page 31: Inspecting And Replacing Tank Vent

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-4 Inspecting and replacing tank vent NOTE: Tank vent prevents a vacuum from forming in fuel tank when fuel in fuel tank is being con- sumed. When pressure in fuel tank becomes too high, tank vent releases the pressure.
  • Page 32 CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-4 Inspecting and replacing tank vent (continued) NOTE: Inspection using 897803-30133 If pressure tester 91139 is not available, tank vent can be inspected with pressure tester 897803- 30133 as follows. 1. Connect tank vent (A) to pressure tester 897803-30133 (B).

  • Page 33: Replacing Purge Bulb

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-5 Replacing purge bulb {Removing} 1. Remove air cleaner cover and air fi lter (Refer to “4-1 Inspecting air fi lter” ). 2. Remove carburetor elbow and carburetor (Refer to “4-8 Testing carburetor” ). 3. Press leg (a1) of purge bulb (A) with screwdriver to remove purge bulb (A) from rear handle.

  • Page 34: Replacing Fuel Line And Fuel Return Line

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-6 Replacing fuel line and fuel return line {Removing} 1. Remove dust cover (Refer to “4-3 Inspecting fuel tank and line”). 2. Disconnect fuel line (A) from black joint (B) and (C). Inspect fuel line (A) and replace with new one if defective.
  • Page 35 CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-6 Replacing fuel line and fuel return line (continued) 13. Reinstall fuel line (D) through grommet (K) as shown. 14.Connect black joint (B), fuel line (A) and (D), respectively. NOTE : Make sure of black joint (B) direction.

  • Page 36: Adjusting Carburetor

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-7 Adjusting carburetor 4-7-1 General adjusting rules A. Before starting the unit for adjustment, check the following items. 1. The correct spark plug must be clean and properly gapped. 2. The air fi lter element must be clean and properly installed.

  • Page 37: Adjusting Carburetor

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-7 Adjusting carburetor (continued) 4-7-3 Adjusting carburetor 1. Start and warm engine for 100 seconds alternat- ing engine speed between WOT 5 seconds and idle 5 seconds. Turn H mixture needle (C) counterclock- wise until engine speed drops to approx. 12,000 r/ min at WOT.

  • Page 38: Testing Carburetor

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-8 Testing carburetor NOTE: To perform this test, carburetor interior should be wet with fuel. If dry, a little leakage may occur. 1. Remove dust cover. 2. Disconnect fuel line (A) from black joint (B).

  • Page 39: Inspecting Crankcase Pulse Passage

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-9 Inspecting crankcase pulse passage 1. Remove carburetor. 2. Drop a little oil in pulse hole (A). 3. Remove spark plug and pull starter grip several times. Oil should spit back from the hole (A).

  • Page 40: Inspecting Inlet Needle Valve

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-11 Inspecting inlet needle valve 1. Remove metering lever (A) and pivot pin. Re- move spring (B) and inlet needle valve (C). 2. Inspect inlet needle valve if worn or sticky. Clean or replace as required.

  • Page 41: Inspecting Diaphragm And Others

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-12 Inspecting diaphragm and others 1. Inspect metering diaphragm (A) for hardening, distortion, or pin hole. Replace as required. 2. Remove pump cover (B), pump diaphragm (C) and pump gasket (D). 3. Inspect pump diaphragm (C) and replace if hardened or curled at valve tabs.

  • Page 42: Installing Carburetor

    CS-2510TES 250Ts, 250TCs FUEL SYSTEM 4-14 Installing carburetor 1. Connect throttle rod (A) to throttole lever (B). 2. Connect purge line (C) and joint (D) on carbure- tor and install fuel inlet (E) to fuel line (F). 3. Pass purge line (C) through tab (G) as shown.

  • Page 43: Clutch System

    CS-2510TES 250Ts, 250TCs CLUTCH SYSTEM 5 CLUTCH SYSTEM (A) Clutch assembly (B) Clutch hub (C) Clutch shoe (D) Spring (E) Clutch plate (F) Clutch drum (G) Needle bearing 5-1 Inspecting clutch parts 1. Loosen nut (A) and remove sprocket guard (B).
  • Page 44 CS-2510TES 250Ts, 250TCs CLUTCH SYSTEM 5-1 Inspecting clutch parts (continued) 4. Rotate clutch assembly (F) clockwise by hand until it cannot be rotated further. 5. Loosen clutch assembly (Left-hand thread) ro- tating clockwise with wrench (G) and remove it. NOTE: Do not use power tools. Otherwise, piston damage may occur.

  • Page 45: Replacing Clutch Parts

    CS-2510TES 250Ts, 250TCs CLUTCH SYSTEM 5-2 Replacing clutch parts 1. Install clutch springs (A) to clutch shoes (B). NOTE : Make sure to have ends of clutch springs (A) face clutch hub (C) 2. Set one arm of clutch hub (C) to one clutch shoe (B).

  • Page 46: Chain Brake System

    CS-2510TES 250Ts, 250TCs CHAIN BRAKE SYSTEM 6 CHAIN BRAKE SYSTEM (A) Brake lever (B) Bolt (M5) (C) Torsion spring (D) Collar (E) Sprocket guard (F) Collar (G) Brake connector (H) Pin (J) Brake band (K) Spacer (L) Compression spring (M) Brake cover...
  • Page 47 CS-2510TES 250Ts, 250TCs CHAIN BRAKE SYSTEM 6-1 Replacing brake lever and torsion spring (continued) 3. Remove bolt (D) , collar (E) and brake lever (F). 4. Remove torsion spring (G) from brake lever (F) 5. Check brake lever (F) if broken, and torsion spring (G) if deformed or broken.

  • Page 48: Inspecting Chain Brake Parts

    CS-2510TES 250Ts, 250TCs CHAIN BRAKE SYSTEM 6-2 Inspecting chain brake parts WARNING DANGER Wear eye protection and safety gloves when disassembling or assembling chain brake to protect eye and hand from injury. {Disassembling} 1. Remove sprocket guard. 2. Move brake connector (A) with ring wrench (B) or other suitable tool as shown.
  • Page 49 CS-2510TES 250Ts, 250TCs CHAIN BRAKE SYSTEM 6-2 Inspecting chain brake parts (continued) 7. Apply molybdenum grease to collar (J). And put collar (J) on boss (K) of sprocket guard. 8. Set brake connector (A), brake band (H) with pin (G) and spacer (M) in sprocket guard as shown .

  • Page 50: Saw Chain Lubrication System

    CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7 SAW CHAIN LUBRICATION SYSTEM (A) Oil cap (B) Gasket (C) Connector (D) Oil tank (E) Oil tank vent (F) Oil strainer (G) Oil line (H) Auto-oiler assembly (J) Oil line (K) Bolt (M4)

  • Page 51: Inspecting Oil Tank Vent

    CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-2 Inspecting oil tank vent        NOTE: Oil tank vent prevents a vacuum from forming in oil tank when chain oil in the tank is con- sumed. 1. Remove starter assembly. 2. Push oil tank vent (A) into oil tank using suitable tool and take out vent (A) from oil tank.

  • Page 52: Inspecting And Replacing Oil Line

    CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-3 Inspecting and replacing oil line {Inspecting and removing oil line} 1. Remove sprocket guard, clutch assembly, clutch plate, clutch drum and needle bearing (Refer to “5-1 Inspecting clutch parts.”). 2. Remove two bolts and muffl er cover (A).

  • Page 53: Inspecting Worm Gear

    CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-4 Inspecting worm gear 1. Remove sprocket guard, clutch assembly, clutch plate, clutch drum and needle bearing (Refer to “5-1 Inspecting clutch parts.”). 2. Remove worm gear (A) and circular washer (B). 3. Inspect worm gear (A) and circular washer (B) for damage, wear or deformation.

  • Page 54: Cleaning And Replacing Auto-Oiler Assembly

    CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-5 Cleaning and replacing auto-oiler assembly {Cleaning and disassembling} 1. Remove sprocket guard, clutch assembly, clutch plate, clutch drum and needle bearing (Refer to “5-1 Inspecting clutch parts.”). 2. Remove muffler cover, oiler cover, worm gear and circular washer (Refer to “7-4 Inspecting worm...
  • Page 55 CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-5 Cleaning and replacing auto-oiler assembly 14. When plunger gear (E) cannot be rotated, ap- ply nail-polish remover (N) to plunger gear (E) on auto-oiler (B) and leave it a few minutes. 15. Tap 5-mm (M5 - Pitch 0.8mm) thread in the hole of plug (P).
  • Page 56 CS-2510TES 250Ts, 250TCs SAW CHAIN LUBRICATION SYSTEM 7-5 Cleaning and replacing auto-oiler assembly (continued) 26. Push in plunger gear (E) with small screw- driver, and hold plunger gear (E) to direction of arrow with fi nger. Remove screwdriver. 27. Install adjuster needle (K) with spring (L) into oiler body.

  • Page 57: Engine

    CS-2510TES 250Ts, 250TCs ENGINE 8 ENGINE (V) (W) (X) (A) Crankcase (L) Snap ring (V) Bolt (M5) (B) Oil seal (M) Piston (W) Spark arrester screen (C) Ball bearing (N) Piston ring (X) Screw (M4) (D) Gasket (Crankcase) (O) Cylinder...

  • Page 58: Testing Cylinder Compression

    CS-2510TES 250Ts, 250TCs ENGINE 8-1 Testing cylinder compression NOTE: Test cylinder compression when engine is cold. 1. Move ignition switch to STOP position. 2. Open cap cover and remove spark plug (Refer to “3-2 Testing spark“). 3. Remove valve core (A) from compression gauge 91037 (B) and insert valve core (A) to adapter X681-000000 (C) with valve core driver (D).

  • Page 59: Cleaning Cooling Air Passages

    CS-2510TES 250Ts, 250TCs ENGINE 8-2 Cleaning cooling air passages 1. Remove starter assembly (A) and fan cover (B). 2. Inspect starter assembly (A) and fan cover (B) for blockage with dirt and/or saw dust. Clean them with wooden or plastic stick or brush or com- pressed air as required.

  • Page 60: Inspecting Muffl Er And Exhaust Port

    CS-2510TES 250Ts, 250TCs ENGINE 8-3 Inspecting muffl er and exhaust port 1. Remove sprocket guard and muffl er cover. 2. Remove three bolts (A), muffler (B), exhaust gasket (C) and exhaust plate (D) from cylinder (E) NOTE : If exhaust gasket (C) stays on muffl er (B), keep them as it is to reuse.

  • Page 61: Testing Crankcase And Cylinder Sealings

    CS-2510TES 250Ts, 250TCs ENGINE 8-4 Testing crankcase and cylinder sealings 1. Remove air cleaner cover, air fi lter and carbure- tor from the unit (Refer to “4-8 Testing carburetor” ). 2. There are two ways to seal intake port and crankcase pulse passage.

  • Page 62: Removing Engine Block

    CS-2510TES 250Ts, 250TCs ENGINE 8-4 Testing crankcase and cylinder sealings (continued)       7. Open cap cover and remove spark plug. 8. Install pressure connector A131-000160 (K) to spark plug hole (L). Connect suitable pipe (inner dia. 4mm) (M) to pressure connector (K).

  • Page 63: Inspecting Cylinder

    CS-2510TES 250Ts, 250TCs ENGINE 8-5 Removing engine block (continued) 4. Remove three bolts (E) from engine cover. 5. Pull out engine block (F) as shown. 8-6 Inspecting cylinder 1. Remove four bolts (A) securing cylinder (B) and remove cylinder (B).

  • Page 64: Inspecting Piston And Piston Ring

    CS-2510TES 250Ts, 250TCs ENGINE 8-7 Inspecting piston and piston ring {Disassembling} 1. Inspect piston ring (A) and replace it if broken, scored, or exceeded service limits (Refer to “1-5 Service limits”). 2. Inspect piston crown (B). Clean with fi ne sand paper, oil stone, and soft cleaning brush (C) if car- bon is found.

  • Page 65: Replacing Oil Seal

    CS-2510TES 250Ts, 250TCs ENGINE 8-7 Inspecting piston and piston ring (continued) NOTE: Make sure to place piston with piston arrow mark (P) pointing as shown. 10. Insert pin guide tool (Q) stamped “8”, through piston (H), with needle bearing (L) and piston pin spacers (M) set at step 9.

  • Page 66: Inspecting Crankcase And Crankshaft

    CS-2510TES 250Ts, 250TCs ENGINE 8-9 Inspecting crankcase and crankshaft   1. Remove cylinder, gasket and piston. 2. Remove woodruf key (A) from crankshaft fly- wheel end (B). 3. Remove three bolts (C) from crankcase assem- bly (D). 4. Set puller Y089-000111 (E) on crankcase as- sembly (D) as shown.

  • Page 67: Replacing Oil Seal And Ball Bearing

    CS-2510TES 250Ts, 250TCs ENGINE 8-10 Replacing oil seal and ball bearing         {Disassembling} 1. After disassembling crankshaft, check ball bear- ing for smooth rotation. If rough, replace it (them) with new one. NOTE: At the same time, replace oil seal with new one.

  • Page 68: Assembling Crankshaft And Crankcase

    CS-2510TES 250Ts, 250TCs ENGINE 8-11 Assembling crankshaft and crankcase 1. Clean mating surface of each crankcase half. 2. Heat ball bearing for easier installation. Then insert crankshaft clutch end (A) into clutch side crankcase half (B) until properly seated. WARNING DANGER When using a heat gun, wear gloves.Other-...

  • Page 69: Installing Piston Ring And Cylinder

    CS-2510TES 250Ts, 250TCs ENGINE 8-12 Installing piston ring and cylinder 1. Completely remove gasket residue on mating surfaces of cylinder and crankcase. 2. If cylinder piece (A) came off from cylinder (B), reinstall it (A) to starter side scavenging port (b1) of cylinder as shown.

  • Page 70: Handle And Control System

    CS-2510TES 250Ts, 250TCs HANDLE AND CONTROL SYSTEM 9 HANDLE AND CONTROL SYSTEM (A) Front handle (B) Rear handle (C) Rear handle lid (D) Torsion spring (E) Throttle trigger (F) Throttle lockout (G) Throttle rod (H) Plug (J) Bolt (M5) (K) Bolt (M4)

  • Page 71: Replacing Throttle Control Parts

    CS-2510TES 250Ts, 250TCs HANDLE AND CONTROL SYSTEM 9-1 Replacing throttle control parts    {Disassembling} 1. Remove starter assembly, sprocket guard, chain catcher, sprocket guard plate, brake lever. (Refer to “6-1 Replacing brake lever and torsion spring“) 2. Remove plug (A) and bolt (B).

  • Page 72: Replacing Front Handle And Spring

    CS-2510TES 250Ts, 250TCs HANDLE AND CONTROL SYSTEM 9-2 Replacing front handle and spring {Disassembling} 1. Remove plug (A) and screw (B). NOTE : If throttle rod is placed over the bolt (B), pull throttle trigger downward. 2. Disconnect front side (c) of front handle (C) from rear handle (D).

  • Page 73: Replacing Rear Handle And Springs

    CS-2510TES 250Ts, 250TCs HANDLE AND CONTROL SYSTEM 9-3 Replacing rear handle and springs {Disassembling} 1. Remove starter assembly, sprocket guard, muffler cover, chain catcher, sprocket guard plate, and brake lever (Refer to “6-1 Replacing brake lever and torsion spring“) 2. Remove rear handle lid and throttle control parts (Refer to “9-1 Replacing throttle control parts”).
  • Page 74 CS-2510TES 250Ts, 250TCs HANDLE AND CONTROL SYSTEM 9-3 Replacing rear handle and springs (continued) 15. Assemble rear handle (G) to unit. NOTE : Make sure to install intake bellows (L) and intake pipe (M) to rear handle (G). 16. Set hook (j) of spring (J) in rib of engine cover and lightly tighten (F) as shown.
  • Page 75 CS-2510TES 250Ts, 250TCs GUIDE BAR MOUNTING SYSTEM 9-3 Replacing rear handle and springs (continued) 25. Insert rear part of rear handle lid (N) to hole (g4) on rear handle (G) as shown. 26. Assemble rear handle lid (N) as rib (g5) on rear...

  • Page 76: Guide Bar Mounting System

    CS-2510TES 250Ts, 250TCs GUIDE BAR MOUNTING SYSTEM 10 GUIDE BAR MOUNTING SYSTEM (A) Nut (B) Hook (C) Sprocket guard (D) Bevel gear (E) Tensioner screw (F) Chain tensioner (G) Bevel gear (H) Cover (J) Sprocket guard plate (K) Bolt (M4)

  • Page 77: Replacing Chain Tensioner

    CS-2510TES 250Ts, 250TCs GUIDE BAR MOUNTING SYSTEM 10-2 Replacing chain tensioner    {Disassembling} 1. Remove bolt (A), sprocket guard plate (B), cover (C), tensioner screw (D), chain tensioner (E), bevel gear (F) and (G) from sprocket guard (H). 2. Check removed parts for damage or wear. Re- place with new part(s) as required.

  • Page 78: Maintenance Guide

    CS-2510TES 250Ts, 250TCs MAINTENANCE GUIDE 11 MAINTENANCE GUIDE 11-1 Troubleshooting guide TROUBLE Engine does not crank. Engine does not start. Fuel leaks. Idling is not stable. Acceleration is poor. Engine stalls at high speed. Engine lacks power. Engine seizure / overheat Engine misfires.
  • Page 79 CS-2510TES 250Ts, 250TCs MAINTENANCE GUIDE 11-1 Troubleshooting guide (continued) INSPECTING REFERENCES Inspecting first. Fuel system / Carburetor 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Air filter Fuel cap / strainer Carburettor adjustment...

  • Page 80: Disassembly Chart

    CS-2510TES 250Ts, 250TCs MAINTENANCE GUIDE 11-2 Disassembly chart Starter Sprocket guard (2-1) Chain Sprocket guard Air cleaner tensioner plate, Starter cover Dust (10-1) Chain catcher pawl cover (6-1) (2-4) Clutch Brake Chain brake Air filter Flywheel lever parts ( 5-1 to 5-3)

  • Page 81: Service Intervals

    CS-2510TES 250Ts, 250TCs MAINTENANCE GUIDE 11-3 Service intervals Intervals Inspecting point Service Reference 3 months 6 months Daily 100 hours 300 hours Screws and bolts * Retighten / Replace Air fi lter Clean Inspect / Replace Carburetor Inspect / Repair...

  • Page 82: Index

    CS-2510TES 250Ts, 250TCs INDEX Air cleaner cover 25, 26, 78 Fuel cap 25, 27, 28, 77 0Pump diaphragm 39 Air fi lter 25, 26, 76, 78, 79 Fuel line 25, 28, 32, 33, 77, 79 Purge bulb 25, 31, 76...
  • Page 84 Published by YAMABIKO Corp. Tokyo Japan 1604...

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