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Table of Contents
- 1 Table of Contents
- 2 Index Technical Data
- 3 Special Tools
- 4 Chain Brake
- 5 Clutch, Clutch Drum
- 6 Oil Pump
- 7 Ignition System
- 8 Starter Assembly
- 9 Carburettor, Intake System
- 10 Cover System, Air Filter
- 11 Vibration Dampers, Handle
- 12 Fuel Tank
- 13 Cylinder and Piston
- 14 Crankcase, Crankshaft
- 15 Checking Operations
- 16 Torques
- Download this manual
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Instruction Manual
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Table of Contents
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Summarization of Contents
Chain Brake System
Chain Brake Operation and Adjustment
Procedures for releasing, relieving tension spring, and pretensioning the chain brake system.
Brake Band Replacement
Guidance on replacing a damaged or defective brake band, including safety caution.
Hand Guard Service
Steps for removing and fitting the hand guard, ensuring correct spring installation.
Clutch Drum Service
Clutch Drum Removal and Disassembly
Procedures for removing the clutch drum, unscrewing the clutch, and noting design variations.
Checking Clutch Drum and Sprocket Wear
Guidance on inspecting clutch drums and sprockets for wear and replacement needs.
Clutch Drum and Clutch Installation
Instructions for mounting the clutch drum and tightening the clutch to the specified torque.
Oil Pump System
Oil Pump Delivery Adjustment
Adjusting the oil pump delivery to regulate chain oil flow using a control screw.
Oil Pump and Intake Pipe Removal
Steps for removing the oil pump housing and the intake pipe from the crankcase.
Oil Pump Wear Inspection and Cleaning
Procedures for checking pump components for wear and cleaning the intake pipe.
Worm Removal from Crankshaft
Using a specialized tool to withdraw the worm from the crankshaft.
Ignition System Service
Spark Plug Check and Maintenance
Procedures for checking spark plug function, continuity, and cleaning or renewing defective plugs.
Spark Plug Terminal Replacement
Steps for removing and installing the spark plug terminal, securing the spring and rubber cap.
Short-Circuiting Switch Service
Instructions for removing and installing the short-circuiting switch and its cable.
Ignition Armature and Flywheel Service
Procedures for removing and installing the ignition armature, including setting the air gap.
Flywheel Installation and Removal
Steps for removing the flywheel using a punch and installing it with correct torque.
Starter Assembly Service
Starter Assembly Removal and Spring Service
Procedures for removing the starter assembly, relieving the return spring, and removing the spring cassette.
Starter Rope Attachment
Method for attaching the starter rope in the rope drum to prevent withdrawal.
Return Spring Pretensioning
Steps for correctly pretensioning the return spring after fitting the starting assembly.
Starter Ratchet Replacement
Instructions for replacing starter ratchets, springs, and pins as a complete assembly.
Carburettor Service
Carburettor Adjustment
Basic and idling speed adjustments for carburettor performance.
Carburettor Removal and Linkage
Steps for removing the carburettor, separating fuel pipe, and detaching choke lever.
Control Lever Alignment
Ensuring the control lever surface is parallel with the carburettor body.
Carburettor Component Service (Tillotson/Walbro)
Disassembly and service of control side components for Tillotson and Walbro carburettors.
Carburettor Pump Side Service
Procedures for servicing the pump side of Tillotson and Walbro carburettors, including fuel filter.
Injection Valve and Intermediate Flange
Removing the injection valve assembly and the intermediate flange.
Cover System and Air Filter
Air Filter Cover Removal
Steps for removing the air filter cover and auxiliary filter cover for cleaning.
Cover Removal for Air Filter Cleaning
Procedure to remove the cover assembly for cleaning the air filter.
Air Filter Cleaning
Instructions for cleaning the auxiliary and main air filters.
Bottom Part Removal
Steps for removing the bottom part, identifying integrated plug and ventilation bore.
Vibration Damping System and Handle
Handle Removal and Fitting
Steps for unscrewing tank screws, removing vibration damper and catching band for handle service.
Vibration Damper Replacement (KS/MS)
Procedures for replacing vibration dampers using specific tools and unscrewing located screws.
Vibration Damping System Design
Description of the three identical vibration dampers on the tank housing.
Damper System Component Design
Details on the fourth vibration damper with pot and catching band.
Fuel Tank System
Fuel Tank Removal and Installation
Steps for removing the fuel tank, separating fuel pipe, and installing seal.
Ventilation Valve Replacement
Procedure for removing the ventilation valve from the tank and ensuring seal integrity.
Fuel Pipe Replacement
Steps for withdrawing the intake head and fuel pipe, ensuring proper sealing.
Intake Head Replacement
Separating the intake head from the fuel pipe and noting felt replacement.
Throttle Lever and Locking System Service
Procedures for removing the throttle lever, locking system, and related springs.
Cylinder and Piston Service
Cylinder Removal
Steps for unscrewing cylinder attachment screws and lifting off the cylinder.
Piston Ring Replacement
Instructions for spreading piston rings, removing the piston, and noting assembly orientation.
Gudgeon Pin and Piston Removal
Procedure for removing the gudgeon pin retaining ring, gudgeon pin, and piston.
Cylinder and Piston Design Variations
Details on die cast and Henkel cylinders, and pistons with one or two piston rings.
Cylinder and Piston Marking
Explanation of identification markings (A, B, C) on precision-machined cylinder and piston assemblies.
Cylinder Installation
Steps for aligning piston rings and compressing them with a tension band during cylinder installation.
Crankcase and Crankshaft Service
Radial Sealing Ring Replacement
Using a tool to screw into the sealing ring and withdraw it from the crankcase.
Crankcase Dismantling
Procedure for dismantling the crankcase and oil reservoir by removing attachment screws.
Crankcase Separation
Separating the crankcase halves using a plastic hammer after removing screws.
Crankcase Halves Division
Description of the crankcase division into magnet side (MS) and clutch side (KS) halves.
Crankcase Assembly
Steps for assembling the crankcase halves, starting with inserting the crankshaft and placing the seal.
Checking Operations
Ignition System Check
Using a tester to check the ignition system and spark plug.
Carburettor Check
In-situ checking of the carburettor by fitting a pressure tester to the connection nipple.
Carburettor and Crankcase Pressure Test
Performing pressure tests on the carburettor or crankcase at a maximum of 0.5 bar.
Torque Wrench Usage
Using a torque wrench for tightening screwed connections like cylinder base screws and flywheel nut.
Crankcase Pressure Test with Cylinder
Pressure-testing the crankcase by blanking off the exhaust duct and connecting to the inlet duct.
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