hbz260ez workshop manual - zenoah

Workshop Manual [2016]

HBZ260EZ

This workshop manual describes the main maintenance items and procedures for the

Husqvarna Zenoah engine blower HBZ260EZ. This manual is classified into three categories.

Special tools for maintenance

Notice of teardown and reassembly

Inspection and adjustment of the carburetor

As reference information, the technical data, the maintenance standard and the

troubleshooting are listed, too.

After each item is thoroughly understood, apply the understanding to the actual maintenance

tasks. Frequently asked questions are also included in this manual. However, many cases

need rich maintenance experience and informed judgment. Please refer to this manual for

maintenance support.

“WARNING”

1. The contents of this manual are based on specifications as of 2016. The contents may be modified due to performance improvement or some other reason without notice.

2. Use Zenoah brand-name parts when replacing a part during maintenance, etc. The manufacturer does not bear any responsibility if trouble occurs owing to use of parts other than those endorsed by our brand.

3. Read this manual thoroughly before beginning the maintenance work, understand it, apply the content to the actual maintenance tasks and guide the customer if directions are needed.

Contents

-１-

1. Features of Engine Blower

1-1 Fan and Volute Case ······························· 2

1-2 Pipes ··················································· 2

1-3 Air Cleaner ············································ 3

1-4 Measures Against Static Electricity ············· 3

2. Strato-charged Engine

2-1 Outline ················································· 4

2-2 Operating Principle ································· 5

3. Constructions - Exploded View ············ 6

4. Technical Data

4-1 Blower ·················································· 7

4-2 External Dimensions ······························· 8

4-3 Pipe and Nozzles ··································· 8

5. Special Tools

5-1 Description ············································ 9

5-2 How to Use ·········································· 11

6. Notice of Teardown

6-1 Isolator Removal ··································· 18

6-2 Carburetor Removal ······························· 18

6-3 Scavenging Port Cove ···························· 19

7. Notice of Reassembly

7-1 Engine Short Block Assembly ··················· 20

7-2 Muffler Installation ·································· 23

7-3 Insulator Installation ······························· 24

7-4 Engine Short Block Installation ················· 24

7-5 Rotor and Ignition Coil Installation ············· 25

7-6 Fuel Pipes Installation····························· 26

7-7 Fuel Tank Installation ······························ 26

7-8 Stop Switch Cords Wiring ························ 27

7-9 Recoil Starter Installation ························· 28

7-10 Cruise Lever Installation ························ 28

7-11 Engine Cover Installation ······················· 29

7-12 Carburetor Installation ··························· 30

7-13 Air Filter Installation ······························ 32

7-14 Fan Installation ···································· 32

7-15 Guard Net Installation ··························· 32

7-16 Recoil Starter Assembly ························ 33

8. Carburetor

8-1 Technical Data······································ 36

8-2 Description ·········································· 37

8-3 Inspection ··········································· 38

8-4 Adjustment ·········································· 41

9. Maintenance Standards/ Tightening Torques

9-1 Standards and Service Ability Limit ··········· 43

9-2 Tightening Torque ································· 44

10. Troubleshooting

10-1 Engine does not star ···························· 45

10-2 Engine stop during operation ················· 46

10-3 Engine cannot be stopped ····················· 46

10-4 Lack of output power or unstable

revolution ·········································· 47

10-5 The amount of the wind is weak ·············· 47

10-6 Others ·············································· 48

-２-


1-1 Fan and Volute Case

Mach data was analyzed and the entrance and exit angles and height of the fan were optimized. A newly

developed high efficiency fan conforming to the engine characteristics reduces the wind separation and the

newly developed high efficiency volute realizes smooth wind flow from the fan. These improvements achieve

the largest air volume (13 m3 / min or more) among the same classes. The high efficiency fan also contributes

to the reduction of annoying noise during operation.

1-2 Pipes

In conventional handy blowers, the reaction force

caused by the misalignment between the handle

position and the pipe position was burdening the

wrist.

This machine adopts S-shaped pipe that reduces the

reaction force by making the handle position and the

pipe position straight, reducing the burden on the

wrist.

S-shaped pipe

Straight

Small inertia moment: Small burden and

easy to operate

Volute Case

Fan

Large inertia moment is burdensome

and difficult to operate.

Misalignment

Conventional Blower

-３-


1-3 Air Cleaner

The two-stage filter unit is installed. The first stage of

urethane filter catches large dust and the second

stage of felt filter catches small dust.

The air filtering efficiency is high and the clog time

has been extended.

1-4 Measures Against Static Electricity

A conductive rubber grip discharges static electricity

through the hands of the operator.

Rubber Grip

Tool-less Knob

Second Felt Filter First Urethane Filter

-４-


2-1 Outline

■ Efforts to the exhaust gas regulations

Husqvarna Zenoah has developed its own "Strato-charged

Engine" as a two-stroke engine compliant with exhaust gas

regulations since 1999, and it has been in compliance with the

regulations of each country starting from the US.

The Strato-charged engine realizes clean exhaust while taking

advantage of two-stroke engine.

■ Structure

Normally, approximately 30% of unburned gas is discharged in a two-stroke engine, because air-fuel

mixture pushes out the combustion gas. However, Husqvarna Zenoah's Strato-charged engine adopts

"air-guided stratified scavenging system" which introduces leading air to the scavenging port separately

from the air-fuel mixture. The leading air pushes out the combustion gas in order to prevent blowing out

of unburned gas resulting in reduction of the concentration of hydrocarbons in the exhaust gas.

■ Features

Because it does not use any special equipment, it is lightweight with a simple structure.

Excellent cooling performance promotes stable output performance even in continuous operation in

summer.

It realizes low fuel consumption of 40% or less. (In comparison with our previous model)

Fresh Air

Air-fuel Mixture

Carburetor

A plate is arranged between the choke

valve and the throttle valve to bring in

the leading air efficiently.

Intake Port

Lead Air Intake Port

Insulator

Scavenging Port

Lead Air

Plate

Piston Groove

-５-


2-2 Operating Principle

1. As the piston proceeds through the upstroke

of the intake cycle, the crankcase vacuum

sucks the lead air in through the scavenging

port via the groove on the piston skirt.

2. As the piston begins its downstroke after top

dead center, a scavenging port starts to open

and lead air in the scavenging port moves into

the cylinder earlier than the air-fuel mixture.

3. As the piston begins its upstroke after bottom

dead center, burnt gas in the cylinder is pushed

out through the exhaust port by lead air.

Therefore, almost no air-fuel mixture is emitted.

Piston Exhaust Port

Burnt Gas

Air-fuel Mixture

Lead Air

Air-fuel Mixture

Lead Air

-６-

3. Constructions - Exploded View

6-2 Carburetor Removal (see page 18)

7-12 Carburetor Installation (see page 30)

8 Carburetor (see page 36)

7-13 Air filter Installation (see page 32)

（32 頁参照）

7-3 Insulator Installation (see page 24)

7-5 Rotor and Ignition Coil

Installation (see page 25)

7-11 Engine Cover Installation (see page29)

7-10 Cruise Lever Installation

(see page 28)

7-9 Recoil Starter Installation (see page 28)

7-16 Recoil Starter Assembly (see page 33)

7-1 Engine Short Block Assembly (see page 20)

7-4 Engine Short Block Installation (see page 24)

7-6 Fuel Pipes Installation (see page 26)

6-3

Scavenging

Port Cover (see page19)

7-2 Muffler Installation (see page 23)

7-8 Stop Switch Cords Wiring (see page 27)

7-14 Fan Installation (see page 32)

6-1 Isolator Removal (see page 18)

7-15 Guard Net Installation (see page 32)

7-7 Fuel Tank Installation (see page 26)

-７-

4. Technical Data

4-1 Blower

Item Unit Specifications

Remarks Category － Handheld Engine Blower

Engine Type － GZ26S61

Blower Model － HBZ260EZ

Cycle － Two-stroke

Number of Cylinders － 1

Valve Type － Piston valve

Cylinder Bore mm 34

Stroke mm 28

Displacement cm3 25.4

Fuel － Lubricating blended gasoline

Engine lubrication － Fuel-oil mixture

Engine lubrication Oil － Two-stroke engine oil

Mixing Ratio － Zenoah FC 40:1/ Zenoah FD 50:1

Carburetor Type － Diaphragm type butterfly throttle valve

Model － RU IXING H226B

Starting Method － Recoil starter (Coil dumper type: EZ)

Ignition System － Digital controlled (CDI) with automatic timing advance IKEDA UK-08977J-502

Ignition Timing BTDC °/rpm 30/ 5,000

Spark Plug Type － NGK BPMR8Y

Gap mm 0.6 to 0.7

Stopping Method Type － Primary coil short-circuiting

Switch － Slide switch

Cooling System － Forced air cooling

Air Cleaner Element Type － Dual layer （Urethane Pre-filter and Felt filter）

Output Axle Rotation Direction － Clockwise View from output axle

Dimensions

Length mm 330

Width mm 220

Height mm 345

Body dry weight kg 3.9 (3.7) ( ): without blower pipes.

Fuel Tank Capacity L 0.45

Idling Speed rpm 3,000 Idling speed stability：±200

Operating Speed rpm 7,300 Wide open throttle

stability：±100

Round Nozzle Diameter mm 68

Average air volume at aimed blowing point

m３/m 13 ANSI

Maximum air speed at aimed blowing point

m/s 73.0 ANSI

(Calculated estimate)

Maximum Output kW/rpm (PS/rpm)

0.85/ 7,300 (1.156/ 7,300)

Fuel Consumption L/h 0.64 Under actual blower state

Ambient noise at 15 m from the blower

dB(A) 70 ANSI B.175.2-2000

Noise at operator (Reference) dB(A) 93

Sound Power Level dB(A) 108 ＩＳＯ２２８６８ (ＨＢＺ２６０)

-８-

4. Technical Data

4-2 External Dimensions

Unit: mm

4-3 Pipe and Nozzles

Unit: mm

Part No. 586 01 82-01 586 01 85-01 586 23 20-01

Name Pipe Round Nozzle Flat Nozzle

Appearance

Outer diam.

D1

Outer diam.

D2

Length

L1

Inner diam.

d3

Inner diam.

d4

Length

L2

Inner diam.

d5

Inner diam.

d6Xd7

Length

L3

φ76 φ76 325 φ76.4 φ68 325 φ76.4 135 X 26 380

-９-

5. Special Tools

5-1 Description

Tool Name Tool Number Appearance Usage

Torx Wrench 578 28 90-01

Size: T20・T25・T27

Bolt and screw loosen/ tighten

Torx Key H502712702

Size: T27

Bolt and screw loosen/ tighten

Gauge 3330-97310

Ignition coil setting (Air gap)

(see page 13)

Stopper 514 24 39-01

Piston head holding (see page 11)

Puller Assy. 587 74 22-01

Rotor removal (see page 11)

Puller bolt: M5

Rotor Removal

Tool H502519401

Rotor removal (see page 11)

Rod Assy. 1101-96220

Piston pin removal or installation

(see page 14)

Pressure Vacuum

Gauge H531030623

Engine seal check (see page 17)

Pressure Tester

Attachment H503844003

Set in the hole of the spark plug, and

connect the pressure gauge (see page 17).

Puller Bolt

（14mm）

（0.3mm）

φ14mm

-１０-

5. Special Tools

5-1 Description

Tool Name Tool Number Appearance Usage

Inlet Cover Plate

Outlet Cover

Plate

582123401

H502541102

Closure of inlet port (see page 17)

Closure of exhaust port (see page 17)

Compression

Gauge (φ14mm)

Adapter Size:

(φ10mm)

H531031686

583 84 98-01

Compression pressure check

(see page 16)

Do not use the adapter for this engine.

Bearing/ Oil Seal

Tool Kit

584 14 05-01

① 581 73 81-01

② 501 71 87-01

③ 848-816-2500

Press the bearings and oil

seals (see page 15).

① Bearing Guide

② Oil Seal Guide

③ Torx Bolt

Crankcase Support

577 41 01-01

When pressing the crankshaft and bearing,

support the crankcase (see page 15).

Assembly pliers 502 50 06-01

Plug cap spring installation (see page 12)

Fuel Filter Hook H502508301

Suspending the fuel filter

Adapter

φ10

Fuel Filter

① ②

③ Part No.

φ12 Marking Part No.

φ12 Marking φ30

-１１-

5. Special Tools

5-2 How to use

Item Procedures

-1)

Rotor Removal

1. Remove the air cleaner cover, engine

cover and the recoil starter.

2. Remove the spark plug and set the

stopper (special tool) to the plug hole of

the cylinder.

3. Remove the mounting nut of the rotor.

NOTE:

Turn the rotor counterclockwise slowly,

contact the piston head to the stopper

(special tool) lightly and loosen the nut.

When loosening the nut suddenly, the

piston head will hit the stopper with

great force and may get damaged.

4. Remove the ratchets from the rotor.

5. Set the puller (special tool) to the rotor.

NOTE:

When attaching the puller bolts, screw

in more than half of the threaded

portion to the rotor.

6. Tighten the center bolt of the puller and

remove the rotor from the crankshaft.

In case of the rotor removal tool of the

special tool is used:

(Do not remove the ratchets from the rotor.)

1. Screw the rotor removal tool to the

crankshaft.

NOTE:

When screwing the tool, make the gap of

the rotor and tool 2 to 3 mm.

2. Hold the rotor by hand, hit the tool with an

iron hammer and remove it from the

crankshaft.

Gap 2 to 3mm

Stopper

Mounting Bolt

Ratchet

Spring

Rotor

Center Bolt (12 mm Hex)

Puller Bolts

Puller

Iron Hammer

Mounting Nut (12 mm Hex)

Rotor Removal Tool

Rotor

-１２-

5. Special Tools

5-2 How to use

Item Procedures

-2)

Fan Removal

1. Remove the volute cover.


stopper (special tool) to the plug hole of

the cylinder.

3. Remove the mounting nut of the fan.

NOTE:

・ Mounting nut is left-threading.

・ Before loosening the mounting nut,

turn the fan clockwise slowly and

contact the piston head to the stopper

(special tool) lightly. When loosening

the nut suddenly, the piston head will

hit the stopper with great force and

may get damaged.

-3)

Plug Cap Spring Installation

1. Set the high-tension cord to the groove on

the guide side of the pliers (special tool).

NOTE:

When setting the cord, do not contact

the guide with the tip of the cord. Make

the gap of the guide and tip of the cord

1mm to 2mm.

2. Make a hole in the center of the high-

tension cord with the pin of the pliers.

3. Insert the long end of the plug cap spring

to the hole of the high-tension cord. Using

the rear groove of the pliers, fix the cap

spring securely.

4. Insert the short end of the plug cap spring

in the other side of the high-tension cord

lightly and fix it securely with the tip of the

pliers.

Pliers Pin

Guide

1～2mm

High-tension Cord

Mounting Nut

Fan

Washer

Washer

Stopper

Plug Cap Spring

Long end

Rear Groove

-１３-

5. Special Tools

5-2 How to use

Item Procedures

-4)

Ignition Coil Installation (Adjusting air gap)

1. Apply thread lock to the mounting bolts.

Set the spacers, the ignition coil and the

terminal, and temporarily tighten the

mounting bolts.

Thread Lock: Three Bond #1342/ 1342H

or LOCTITE #242 or equivalent

2. Insert the gauge (special tool) between the

rotor magnet metal and ignition coil.

Tighten the mounting bolts while pushing

the ignition coil against the rotor.

Torque: 2.5～3.5N･m (25～35kgf･cm)

NOTE:

When contacting the iron core of the

ignition coil and part of the rotor magnet

metal, the engine may stop suddenly.

Secure the air gap (03.mm) using the

gauge.

[Resistance]

The resistance values shown above are the reference values for resistance tester

measurement. The resistance value within the normal range shows no internal leakage or

any other defect.

Ignition Checker (Tool No. 3699-90247)

We supply the measurement

equipment (Ignition Checker) that can

measure spark energy while the

engine is running. When measuring

the spark energy, discharge gaps are

different depending on the connected

place of the alligator clip.

Refer to the ignition checker

manufacturer’s instruction details.

Resistance (Reference)

Air Gap Primary side

(Iron Core ↔ Primary Terminal) Secondary Side

(Iron Core ↔ Secondary Side)

90kΩ±20％ 4kΩ±10％ 0.3mm

Rotor

Mounting Bolts M4x 12L (T27)

Gauge

(0.3mm) Ignition Coil Spacers

Identifi- cation No.

Parts No.

Iron Core

High-tension Cord

Primary Lead

0.3ｍｍ

0.3ｍｍ

Discharge Window

If connected to the engine.

Discharge gaps: 6mm

Plug Cap

If connected to the spark plug.

Discharge gaps: 4mm

Discharge Gap Adjustment Knob

-１４-

5. Special Tools

5-2 How to use

Item Procedures

-5)

Piston Pin Removal/ Installation

1. Remove the cylinder from the engine short

block.

2. Remove the snap rings from both sides of

the piston.

3. Insert the rod assy. (special tool) to the

piston pin, remove the piston pin from the

piston while gently tapping it with a plastic

hammer.

NOTE:

Hard hammering may damage the big

end of the connecting rod.

4. When installing the piston pin, set it to the

rod assy. (special tool). Insert the piston

pin to the position of the snap ring

groove.

Piston Pin Rod Assy.

Snap ring grooves

Rod Assy. Snap Rings

Big end of the

Connecting rod

Piston Pin

Piston

-１５-

5. Special Tools

5-2 How to use

Item Procedures

-6)

Bearing and Oil Seal Installation

Illustration shows the MAG side. PTO side similar.

Press of Bearing:

1. Set the support (special tool) outside of

the crankcase, tap the bearing with a

plastic hammer lightly and fit it into the

crankcase horizontally.

2. Insert the bearing guide (special tool) in

the bearing and set the oil seal guide

(special tool) from the other side of the

crankcase and fix it with the bolt (special

tool).

3. Fix the bearing guide with a wrench and

press the bearing to the crankcase while

tightening the bolt.

NOTE:

Press the bearings until they contact

the crankcase. If the bearing is not

level to the dotted line of the

crankcase, rotation of the crankshaft

will be off-balance.

Press of Oil Seal:

4. Remove the oil seal guide from the

bearing guide, and insert the oil seal to

the bearing guide.

5. Set the oil seal guide and fix it with the

bolt. Fix the bearing guide with a wrench,

hold the oil seal guide and press the oil

seal to the crankcase while tightening the

bolt.

Oil Seal Guide Oil Seal

Oil Seal Guide

Bearing

Bolt

Bearing Guide

Bolt

Bearing Guide

Oil Seal

Oil Seal Guide

Bearing Crankcase

Bolt

Bearing Guide Oil Seal Guide

Contact the crankcase.

Bearing

Crankcase

Support

-１６-

5. Special Tools

5-2 How to use

Item Procedures

-7)

Crankshaft Installation

Set the support (special tool) outside of the

fan side crankcase and insert the crankshaft

to the crankcase.

NOTE:

When inserting the crankshaft, do not

damage the lip of the oil seal at the edge

of the crankshaft.

-8)

Compression Pressure Check

1. Warm-up the engine for at least 5 minutes.

NOTE:

After warm-up, the engine and the

muffler will become hot. Be careful

not to burn yourself.

2. Remove the attachment from the

compression gauge.


compression gauge (special tool) to the

cylinder.

4. Pull the recoil knob quickly and strongly

about 5 times.

More than 7.0 kg/cm2 (686kPa) is fine.

“This value is only an estimate.”

NOTE:

Engine parts is not thermal expansion

in the warm-up the shortage, or

immediately after replacement with the

new part, cannot be to correctly

measure the compression pressure.

Support

Crankshaft

Crankcase

Attachment Do not use.

Compression Gauge (φ14mm)

Compression Gauge

-１７-

5. Special Tools

5-2 How to use

Item Procedures

-9)

Engine Seal Check

1. Remove the air cleaner, the carburetor

and the insulator.

2. Attach the inlet cover plate (special tool)

and the gasket with the bolts. Tighten the

bolts, then close the intake port of the

cylinder.

Bolt size: M5×12mm or less (3)

3. Remove the spark plug, set the pressure

tester attachment (special tool) to the

cylinder.

4. Remove the muffler and the gasket.

5. Temporarily install the muffler and set the

outlet cover plate (special tool) to between

the exhaust port of the cylinder and the

muffler. Tighten the bolts, then close the

exhaust port.

If necessary, cut the outlet cover plate so

that the exhaust port is closed surely.

6. Connect the pressure vacuum gauge

(special tool) to the pressure tester

attachment of the cylinder.

7. Adjust the "Pressure Mode" press to

80 kPa.

After 30 seconds, if the seal stays at

60 kPa, the sealing should be fine.

Select Knob

Pressure Mode

Vacuum Mode

Pressure Tester Attachment

Gasket

Outlet Cover

Plate

Gasket Muffler

Pressure Vacuum Gauge

Select

Knob

Inlet Cover

Plate

-１８-


6-1 Isolator Removal

1. Remove the volute cover and the assist handle.

2. Pull out the isolator from the volute case.

6-2 Carburetor Removal

1. Remove the mounting bolts, then remove the

filter housing from the carburetor, and pull out the

priming pump.

2. Disconnect the suction pipe and the fuel pipe

from the carburetor.

NOTE:

Put a protective tape to the tip of the pliers, and

prevent damage to the suction pipe.

Suction Pipe

Filter Housing

Gasket

Carburetor

Gasket

Priming Pump

Fuel Pipe

Volute Cover

Assist

Handle Volute Case

Isolator

-１９-


6-2 Carburetor Removal

3. Lift the carburetor and disconnect the throttle

rod from the throttle link.

6-3 Scavenging Port Cover

NOTE:

The mating surfaces of the scavenging port

cover and the cylinder are of a very high sealing

precision. Because it is difficult to secure the

sealing accuracy in mass production, do not

remove the scavenging port cover.

Scavenging Port Cover

Throttle Rod

Throttle Link

-２０-


Notice of Reassembly

7-1 Engine Short Block Assembly

1) Lubricating and Degreasing

Apply two-stroke engine oil to the inner surface of the main bearings, needle bearing, between the crank

weight and the connecting rod large end.

Apply two-stroke engine oil to the inner surface of the cylinder and the outer periphery of the piston

excluding the piston head.

Apply heat-resistant grease No.2 to the inner surface and lip of the oil seals.

Degrease the outer surface of the main bearings and the bearing contact surface of the crankcase.

Degrease the taper and thread portion of the crankshaft.

Degrease the outer surfaces of the oil seals.

Piston

Cylinder

Needle Bearing

Bolts (4) M5x 20L (T27)

Torque: 6.0～8.0 N・m (60～80kgf・cm)

Snap Ring Fan side

Piston Pin

Bolts (3) M5x 20L (T27)

Torque: 6.0～8.0 N・m (60～80kgf・cm)

Oil Seal

Starter side

Crankcase

（Starter side）

Oil Seal

Two-stroke oil applying location

Degreasing location

Crankcase

Oil Seal

Crankcase

（Fan side）

Degreasing

Degreasing

Degreasing

Bearing

Connecting rod

large end

Bearing

-２１-



2) Main Bearing and Oil Seal

Press the main bearings and the oil seals with

the tool kit of special tool (see page 15).

3) Crankshaft

When inserting the crankshaft, set the support

(special tool) to the outside of the fan side

crankcase (see page 16).

When installing the starter side crankcase,

align the crankcase gasket exactly to the

mating surface of the crankcase.

NOTE:

When inserting the crankshaft, do not

damage the lip of the oil seal at the edge of

the crankshaft.

4) Crankcase Gasket

NOTE:

Be sure to use the new parts of the

crankcase gasket.

Cut off the crankcase gasket ends exceeding

the cylinder mating surface.

When cutting the gasket, cut it outward from

inside, so that the gasket will not fall into the

inside of the crankcase.

Cut off.

Crankcase

Crankcase Gasket

Oil Seal

Lubrication holes Not clogged.

Oil Seal

0.5～1mm 0.5～1mm

Bearings (Contact the crankcase.)

Crankshaft

Starter side Crankcase

Fan side Crankcase

Support

Starter side crankcase Fan side Crankcase

Lubrication holes

Crankcase Gasket

-２２-




5) Piston Ring

Align the end gap of the piston ring exactly with

stopper pin of the piston.

6) Piston, Piston Pin and Snap Ring

Make sure to point the triangle mark on the

piston head to the exhaust (muffler) side.

Install the piston pin with the rod assy. of

special tool (see page 14).

Fit the snap ring in the groove of the piston

firmly and turn the end gap of the snap ring to

the opposite side of the notch.

After the assembly, check that it moves

smoothly in the groove by turning the snap

ring with a thin tool of the tip. If the snap ring is

not securely fitted into the groove, it does not

move smoothly.

NOTE:

If the snap ring does not fit properly into

the groove or the end gap of the snap ring

is incorrectly positioned, and the snap

ring come off during operation, it may

damage the engine.

Never reuse the snap ring, replace it with a

new one.

7) Cylinder Gasket

When setting the cylinder gasket, make the

arrow mark to the rotor side.

Triangle Mark

Exhaust side

Snap Ring

Groove

Piston Pin

End Gap

Notch

Piston Stopper Piston

Piston Ring

Arrow Mark Cylinder Gasket

-２３-


7-2 Muffler Installation

Check the muffler for deformation and cracks. If

necessary, replace it with a new one.

Remove the carbon deposits that have

accumulated in the muffler with a screwdriver.

NOTE:

Do not burn the carbon deposits in the muffler

by overheating with the gas torch. If

overheated, it may cause deformation of the

muffler, melting of the inner glass wool, etc.

Remove the carbon deposits on the engine side

exhaust port with the wood stick.

NOTE:

Block the exhaust port with the piston so that

carbon deposits does not fall in the cylinder.

Check that the diffuser mounting bolts are fastened

securely.


Set the muffler gasket in the proper direction as

shown.

Evenly tighten the muffler mounting bolts.


When reusing the muffler gasket:

Check the muffler gasket, and if there are no

deformations or cracks it can be reused.

Peel off the expanded graphite gasket remaining

in the muffler gasket, and apply the heat-resistant

liquid gasket to the mating surfaces of the cylinder

and the muffler.

Liquid gasket:

Three Bond #1217C or equivalent

Muffler

Expanded Graphite

Gasket

Bolts (2) M4x 8L (T27)

Diffuser

Bolts (2) M5x 20L (T27)

Muffler Gasket

Muffler

Exhaust Port

Muffler Gasket

-２４-



7-3 Insulator Installation

Check the insulator for deformation, cracks, and

seal detachment. If necessary, replace it with a

new one.

Set the insulator gasket in the proper direction as

shown.

Evenly tighten the insulator mounting bolts.

Thread Lock: Three Bond #2353 or LOCTITE

#242 or equivalent


NOTE:

Do not pinch the end of the seal between the

insulator and the crankcase.

7-4 Engine Short Block Installation

When installing the cylinder plate, check that the

edges of the muffler gasket and the insulator are

inside of the cylinder plate.


Align the holes in the crankcase and the

projections of the volute case, and install the

engine short block to the volute case with the

mounting bolts.


NOTE:

Do not pinch the seal of the insulator between

the volute case and the engine short block.

Crankcase

Insulator Gasket

Bolts (3) M5x 20L (T27)

Insulator

Seal

Do not pinch this portion.

Bolts (3) M5x 22L (T27)

Engine Short Block

Seal

Volute Case

Projections

Cylinder Plate

Screws (2) M5x 8L (T27)

Insulator

Muffler Gasket

Insulator

Engine Short Block

Volute Case

-２５-


7-5 Rotor and Ignition Coil Installation

1. Set the stopper (special tool) to the plug hole of

the cylinder (see page 11).

2. Parallel the flat surface of the key to the center

line of the crankshaft, and set it in the keyway of

the crankshaft. Align the keyway of the rotor with

the key to crankshaft surely and insert it.

NOTE:

Make sure that there is no adhesion of oil or

dust on the tapered surface and the threaded

portion of the crankshaft and rotor.

3. Tighten the mounting nut and fix the rotor.

Torque: 10～15N･m (100～150kgf･cm)

NOTE:

When removing the rotor by using the puller

(special tool), and after attaching the rotor,

confirm the operation of the ratchet and the

springs are set in the correct position (see

page11).

Torque: 3～4N･m (30～40kgf･cm)

4. Apply thread lock to the mounting bolts.

Set the spacers, the ignition coil and the

terminal, and temporarily tighten the mounting

bolts.

Thread Lock: Three Bond #1342/ 1342H or

LOCTITE #242 or equivalent

5. Insert the gauge (special tool) between the rotor

magnet metal and ignition coil. Tighten the

mounting bolts while pushing the ignition coil

against the rotor.

Torque: 2.5～3.5N･m (25～35kgf･cm）

6. Set the switch cords to the guide of the insulator,

securely fix the grommet of high tension cord to

the notch of the cylinder plate.

Ignition Coil

Spacers (2)

Bolts (2) M4x 25L (T27)

Terminal

Rotor Switch Cord

Gauge (0.3mm) Grommet

Rotor

Crankshaft

Key

Parallel

Mounting Nut

Ratchet

Bolts (2) M5x 12L (T27)

Rotor

Stopper

-２６-



7-6 Fuel Pipes Installation

Before installing the fuel pipes,

inspect the dirt of the fuel filter.

If the bottom surface of the

filter is considerably dirty and

the entire filter has turned

black, replace it with a new

one. When reusing the dirty

filter, the suction of the priming

pump will be poor, and the fuel

which the priming pump sucks

in decreases.

When installing the fuel pipes, align the A-mark of

the pipe grommet and the triangle mark of the fuel

tank.

NOTE:

The pipe grommet has a triangle mark (△) in

addition to the A-mark, but always be sure

to align it to the A-mark. If it is not aligned to

the A-mark, the fuel pipe may be twisted and

the fuel filter may not be in the proper

position.

Make sure that the protruding length from

the grommet is the specified dimension. If

protrudes too much or extends too little,

pipe bending and/or poor fuel filter

response may occur.

7-7 Fuel Tank Installation

1. Attach the fuel tank to the volute case.


NOTE:

If there are a rattle and deformation to the

collar of the fuel tank, replace the fuel tank

with a new one.

2. Align the white mark of the suction pipe to the

guide groove upper edge of the volute case, and

set it to the volute case.

3. Fix the pipe to the volute case with the clamp.


White Mark

Suction Pipe (black)

Return pipe (yellow)

長

す

ぎ

た

り

、

短

す

ぎ

た

り

す

る

と

、

フ

ィ

ル

タ

ー

の

追

従

性

が

悪

く

な

る

恐

れ

が

あ

り

ま

す

。

長

Pipe Grommet

175mm

118mm 55mm

Fuel filter

Fuel Tank

Collar

Pipe Grommet A-mark

Triangle Mark

Triangle Mark

Fuel Tank

Align.

Fuel Tank

Screws (2) TP5x 20L (T27)

Screw TP M5x 20L (T27)

Suction Pipe

White Mark

Clamp

Fuel Filter

-２７-


7-8 Stop Switch Cords Wiring

Install the switch cords securely as shown in the figure below.

Stop Switch

In the correct direction, and insert all the way.

Insert all the way into the guide groove.

Insert all the way into the guide groove.

Terminal Fit onto the projection.

Ferrite Core

Fit onto the guide.

Grommet

Insert all the way.

NOTE:

When wiring the switch cords, make the ground cord (black) to the volute case side.

Grommet

Insert all the way. Insert all the way into the guide groove.

-２８-



7-9 Recoil Starter Installation

Fit the recoil starter to the crankcase, and fix it

with the mounting bolts.


When fitting the recoil starter to the engine case,

engage the ratchet of the rotor and cam plate

hook of the recoil starter while pulling little starter

knob.

NOTE:

If there are a rattle and deformation to the

collar of the recoil starter, replace the recoil

starter case with a new one.

7-10 Cruise Lever Installation

1. Set the wave washer to the engine cover.

Align the stopper portion of the ratchet at the

cruise lever operation range (A) of the cover and

insert the ratchet in the hole of the cove.

2. While holding the ratchet from the inside of the

engine cover, align the convex of the cruise lever

to the concavity of the ratchet, and tighten the

mounting bolt.

Cruise lever operating torque:

3.0～4.5N･m (30～45kgf･cm)

Recoil Starter Bolts (3) M5x 16L (T27)

Ratchet

Wave Washer

Stopper

Engine Cover

Cruise Lever

Ratchet

Bolt M5x 22L (T27)

Collar

(A)

Ratchet

Cruise Lever

-２９-


7-11 Engine Cover Installation

1. Connect the throttle rod to the throttle lever and

insert it to the boss of the volute case.

2. Set the projection of the ratchet and the throttle

lever at the idling position shown in the figure

and assemble the engine cover to the volute

case.


3. Connect the switch cords, and make sure to

push the switch cord to the clamp of the engine

cover one by one so that the switch cord does

not come off.

Throttle Rod

Throttle Lever

Projection

Switch Cords

Screws (6) TPM5x 20L (T27)

Ratchet

Engine Cover

Throttle Lever

-３０-



7-12 Carburetor Installation

1. Apply grease to the throttle link and connect the

throttle rod to the throttle link.

Grease: Lithium grease No. 2 or equivalent

2. Connect the fuel pipe to the short nozzle of the

priming pump, and connect the return pipe to the

long nozzle.

3. Connect the fuel pipe to the carburetor, and fix it

with the clip.

4. Set the gasket and carburetor to the mounting

position.

5. Apply grease to the sliding portion of the choke

knob and insert it to the filter housing while

pushing the hook. Make sure that it will not come

out by pulling the choke knob.

Grease: Lithium grease No. 2 or equivalent

Carburetor

Clip

Priming Pump

Return Pipe

Choke Knob

Hook

Hook

Filter Housing

Throttle Rod

Throttle Link

Gasket

Fuel Pipe

-３１-


7-12 Carburetor Installation

6. Set the gasket to the carburetor in the proper

direction as shown. Connect the choke shaft pin

to the notches of the choke knob, and

temporarily install the filter housing to the

carburetor.

7. Make sure to fix the carburetor, the gasket and

the filter housing with the mounting bolts.


8. Pass the pipe through the primer pump mounting

part of the filter housing, and secure the primer

pump to the filter housing while the fuel pipe is

facing up.

9. Connect the suction pipe to the carburetor.

NOTE:

Apply the protective tape to the tip of the

pliers, do not damage the suction pipe.

10. After installing the carburetor, make sure that the

throttle and choke are operating properly and

each pipe is not bent.

Suction Pipe

Carburetor

Priming Pump

Fuel Pipe

Filter Housing

Choke Shaft Pin

Notch

Gasket

Bolts (2) M5x 55L (T27)

Carburetor

Filter Housing

-３２-



7-13 Air filter Installation

Set the plate and the felt filter to the filter housing,

and set the urethane filter to the air cleaner cover.

Install the plate and the filters in the proper direction

as shown in the figure.

NOTE:

Use neutral detergent and warm water to

clean the filter. After cleaning, air dry the filter

completely and install it.

If the felt filter is dirty, replace it with a new

one.

If the filter is deformed or damaged, replace it

with a new one.

7-14 Fan Installation

1. Set the stopper (special tool) to the plug hole of

the cylinder (see page 11).

2. Install to the crankshaft in the order of the

washer, the fan and the washer.

3. Tighten the fan with the mounting nut.

Torque: 14.7～17.6N･m (150～180kgf･cm)

NOTE:

Mounting nut is left-threading.

Make sure that there is no adhesion of oil

or dust on the crankshaft and the washer.

7-15 Guard Net Installation

Fit the guard net in the proper direction as shown in

the figure and fix it to the volute cover with mounting

screws.


NOTE:

If the guard net is deformed or damaged, do not

reuse. The fan and deformed portion of the

guard net might damage each other by contact,

and broken pieces may cause injury or accident

by entering the inside of the volute case.

Felt Filter

Air Cleaner Cover

Plate

Urethane Filter

Nut

Fan Washer

Stopper

Guard Net Screws (3) TPM5x 20L (T27)

Washer

-３３-


7-16 Recoil Starter Assembly

1. Hang the spring hook (a) of the return spring to

the notch of the spring case. Next wind the return

spring in the counterclockwise, and store it in the

spring case.

2. Set the spring case which stores the return

spring to the recoil case.

NOTE:

Securely insert the spring hook (a) of the

return spring into the groove of the recoil

case. Make the gap of the spring hook (b)

and the boss of the recoil case about 2mm.

Apply grease to the boss.

Grease:

Cold-resistant grease No. 2 or equivalent

3. Insert a rope through the reel as shown in the

figure and tie a knot at position of about 10mm

from the end of the rope. Push the knot of the

rope in the groove of the reel.

Reference:

This model uses rope size of φ 3.5×700-

800mm

Wind up.

Notch

Return Spring

Spring Hook (a)

Spring Case

10mm

Knot

Reel Rope

Groove

Spring Hook (a) Boss

Groove

(Recoil Case)

Spring Case

2mm

Spring Hook (b)

-３４-




4. Wind the rope to the reel clockwise, and hang

the rope to the notch of the reel.

However do not wind up all the rope, leave about

25 to 30cm from the notch of the reel.

5. Apply grease to the inner surface of the reel.

Insert the reel with the wound rope to the boss of

the recoil case. When inserting the reel, engage

the spring hook (b) to the groove under the reel.

Grease:

Cold-resistant grease No. 2 or equivalent

Reference:

Normally set the groove on the bottom side

of the reel to be positioned opposite to the

notch.

6. Lightly turn the reel clockwise, and make sure

the groove and the spring hook (b) are engaged.

If engaged correctly, the reel will return to its

original position by the force of the return spring.

7. Set the damper spring in the reel and install the

cam plate with a mounting screw.

Torque: 2.9～3.9N･m (29.6～39.8kgf･cm)

About 20 to 30cm

Notch

Rope

Reel Wind up clockwise.

Screw

Cam Plate

Damper Spring

Reel

Reel

Notch

Boss

Groove

(Reel side)

Spring Case

Spring Hook (b)

-３５-



8. Pull out the rope from rope guide of the recoil

case, and insert it through the knob. Knot the

rope end eight times to produce a rounded rope

end knot and push the knot to the inside of the

knob.

9. Pull the rope up into the notch in the reel, turn

the reel 4 to 5 times clockwise and hold the reel

with your thumb.

10. Detach the rope from the notch of the reel,

stretch it with the knob, and release the thumb

and slowly wind up the rope to the reel with the

spring tension.

NOTE:

When the rope is fully pulled out, make

sure that the reel rotates 1 to 1-1 / 2

clockwise.

If the reel rotates 1-1/2 or more, increase by

1 the number of winding of the rope.

If the reel dose not rotation 1 time, reduce

by 1 the number of winding of the rope.

Hold this portion.

How to knot a rope：

Knot

Knot the rope end eight

times to produce a rounded

rope end knot.

Knob

Recoil Case

Rope

Rope Guide

Rope

Notch

Reel

1 to 1-1/2 rotations

-３６-

8. Carburetor

8-1 Technical Data

Item Specifications

Blower Model HBZ260EZ

Model RUIXING H226B

Part Number 586 23 19-01

Basic Adjustment Turns※1 L-needle※2 2 - 3/4

H-needle※3 2

Metering Lever height mm 0 ±0.15

Venturi diam. Lead air

φmm 11.10 Air-fuel mixture

Bore diam. Throttle valve side φmm 14.3

Choke valve side φmm 18

Inlet Valve

Opening pressure kgf/cm2

（kPa） 1.2～3.2 (117～310)

Reseating pressure kgf/cm2

（kPa） 0.56 (55)

Idling speed range rpm 2,800～3200

No-load maximum speed range rpm 7,200～7,400

Rich down range rpm 600

※1:Tighten then loosen

※2: Low Speed Mixture Needle

※3: High Speed Mixture Needle

Required Tools

① Pressure Gauge

3699-90211

② Driver (For mixture needle adjustment)

2670-91150

③ Tachometer

PET-1000

3699-90537

④ Tachometer

PET-2000DXR

3699-92470

Carburetor Cleaner

-３７-

8. Carburetor

8-2 Description

If the carburetor is malfunctioning, adjust the fuel and inspect the damage of the component parts.

If engine speed is not stable and has bad acceleration, adjust the mixture needles according to the item “8-4

Adjustment”.

L-needle

Adjustment of the low and medium engine

speed.

Turn direction Fuel

Clockwise lean

Counterclockwise Rich

Friction Piece (Plug)

Idle Adjustment Screw

Pump Cover

Gasket Throttle Valve

Pump

Diaphragm

Plate Choke Valve

Inlet Valve

Metering Lever

H-needle Gasket

Metering

Diaphragm

Cover

H-needle

Adjustment of the high engine speed.

Turn direction Fuel

Clockwise lean

Counterclockwise Rich


Adjustment of the idle engine speed.

Turn Direction Speed

Clockwise Increases

Counterclockwise Decreases

L-needle

-３８-

8. Carburetor

8-3 Inspection

1) Metering Diaphragm

・Check the metering diaphragm for damage

and stiffness. If necessary, replace it with a

new one.

・Check that the convolution height of metering

diaphragm does not become flat. When

convolution height is flat, replace the metering

diaphragm with a new one.

2) Pump Diaphragm

・Check the pump diaphragm for damage and

stiffness. If necessary, replace it with a new

one.

・Because the pump diaphragm is made of film

material, when the valve portion is warped, it

does not return to the original state. Be sure to

replace it with a new one.

3) Inlet Valve Leaking Test

・Connect the pressure gauge (special tool) to

inlet port of the carburetor body and fill the

metering chamber with fuel. Apply pressure to

the inlet valve and read the opening pressure

and the reseating pressure.

Opening pressure:

1.2～3.2kgf/ cm2 (117～310kPa)

Reseating pressure:

0.6kgf/ cm2 (55kPa) or more

・If the reading is out of the specified standard,

check the item "4) Metering Lever and Inlet

Valve".

Pump Diaphragm

Metering Diaphragm

Convolution Height

This portion not flat.

Pressure Gauge

Air Pump

Metering Chamber

Valve Portions

-３９-

8. Carburetor

8-3 Inspection

4) Metering Lever and Inlet Valve

・Measure the metering lever height using a

depth gauge or scale.

Specified standard: 0±0.15mm

・If the reading is out of the specified standard,

repair the metering lever or replace it with a

new one

・Check the wear of the contact portion of the

metering lever and the metering diaphragm. If

necessary, replace them with new parts.

・Check the lever shaft, and if it is rusted replace

it with a new one.

・Remove the inlet valve and check for dirt,

sludge, rusting and/or step-wear. Replace the

inlet valve if a beveled edge is found on the

rubber tip.

・Inspect the clogging of the fuel passage in the

carburetor body and make sure there are no

dirt on the pump cover. If necessary, dip the

carburetor body and the pump cover in

gasoline for about 10 minutes, or clean them

using carburetor cleaner.

・When setting the spring, be careful not to bend

it.

5) Main Check Valve

・Make sure to check the main check valve in

case fuel is not supplied though the priming

pump when operated.

・Press the vinyl pipe (inner diameter:φ5mm)

against the main check valve and blow and

suck with mouth.

[A]: Open by blowing

[B]: Stop by sucking

Main check valve has no failure.

・In case of failure, soak the carburetor body into

gasoline for about 10 minutes and repeat

blowing and sucking several times. If this is not

successful, replace the carburetor assembly.

NOTE:

Do not clean the main check valve with

compressed air. If the main check valve is

cleaned by compressed air, it may not

function properly.

Check of the wear.

Not good

Metering Lever 0±0.15mm

Carburetor

Body

Valve Seat

Lever Shaft

Inlet Valve

Metering Diaphragm Step-wear

Clogging

Plastic Pipe

(Inner diam.φ15mm)

Main Check Valve

[A] [B]

Bending of the spring.

-４０-

8. Carburetor

8-3 Inspection

6) Screen

Inspect the screens for clogging, be sure to

clean if the dust is adhered.

7) Gaskets

When assembling the new metering diaphragm

and the new pump diaphragm, be sure to

replace the gasket with new parts at the same

time.

Screen

New Gasket

New Pump Diaphragm

New Gasket

New Metering Diaphragm

-４１-

8. Carburetor

8-3 Inspection

8) Needles and Screw

・Remove the high speed mixture needle, the

low speed mixture needle, and idle adjustment

screw, and check the wear/ damage of the tip

and thread portions. If necessary, replace them

with new parts.

・Check the rattling of the idle speed throttle

valve screw. If rattling, push the friction piece

(plug) with a tip of the wire, and replace it with

a new one.

8-4 Adjustment

1) Initial Start Settings

First tighten L and H needles clockwise (CW)

gently until they are seated. And then turn each

needle counterclockwise (CCW) from the seated

position to set each needle to be the basic

adjustment turns.

Basic adjustment turns

L-needle H-needle

2- 3/4 2

2) Warm-up

Standard pipe and nozzle must be installed

properly. Start the engine and alternate three

times between the idling state (10 seconds) and

wide open throttle (60 seconds).

High Speed

Mixture Needle


Low Speed

Mixture Needle

H-needle

L-needle

Wire

Friction Piece (Plug)

-４２-

8. Carburetor

8-4 Adjustment

3) Low Speed Mixture Needle Adjustment

① Turn the L-needle clockwise (CW) or counter-

clockwise (CCW), to adjust so that the engine

speed is the maximum speed.

② Adjust the engine speed at 3,600±200 rpm

(peak idling) with the idle adjustment screw.

③ Set the engine speed at 3,000±200 rpm by

turning the L-needle counterclockwise (CCW).

Rich Down 600rpm

4) High Speed Mixture Needle Adjustment

Accelerate engine to wide open throttle, adjust

the engine speed at 7,300±100 rpm by turning

the H-needle clockwise (CW).

NOTE:

If engine speed is too high, the output

decreases.

Target RPM

Rich Down

Con

su

mp

tio

n L

/h

Engine speed (rpm)

3000±200rpm Peak Idling

Rich Down:

Adjust the L- needle to a slightly richer

mixture in order to maintain a stable

idling speed and get a good acceleration.

②


L-needle

③

①

H-needle

-４３-


9-1 Standards and Service Ability Limit

Maintenance Item Unit Standard Limit ※1

Measuring Procedure

Cylinder

Compression pressure kgf/cm² （kPa）

7.0 4.0 CPG Cylinder/ Piston ring Replace.

Bore mm φ34 ※2 CG Expose of base

metal: Replace.

Piston

Piston skirt diameter mm φ33.963～φ33.943 φ33.88 MM Replace.

Piston ring

groove width

Top mm

1.03 1.1 TG Replace.

2nd 1.01 1.1

Piston pin hole mm φ8 φ8.4 CG Replace.

Clearance between piston

and cylinder mm 0.037～0.082 0.15

MM CG

Piston

Replace.

Clearance

between piston

groove and

piston ring

Top

mm

0.04～0.08 0.1

TG Replace.

2nd 0.02～0.06 0.1

Fitting between piston pin

and piston pin hole mm 0.005～0.021 0.05

MM CG

Replace.

Piston Ring End gap at cylinder skirt mm 0.10～0.30 0.5 TG Replace.

Width mm 1.0 0.9 MM Replace.

Piston Pin Diameter mm φ8 φ7.98 MM Replace.

Connecting Rod

Small end bore mm φ11 φ11.05 CG Replace.

Parallelism of large/ small

end bores 0 0.15/ 100※3

Mandrel DG

Replace.

Crankshaft

Diameter at

main bearing

MAG mm

φ12 φ11.97 MM Replace.

PTO φ12 φ11.97

Diameter at oil seal

(MAG，PTO) mm φ12 φ11.9 MM Replace.

Eccentricity mm 0 0.07※4 （@ 4） DG

Center Support

Repair or replace.

Width between crank

webs mm 22 21.9～22.1 MM Repair or replace.

Axial Play mm 0.058～0.382 0.5 TG Replace.

Main Bearing －－ ※5 － Replace.

※1 Meaning of abbreviations

CG：Cylinder Gauge/ MM：Micrometer/ DG：Dial Gauge/ TG：Thickness Gauge/ CPG：Compression gauge

※2 Peel off of plating or expose of base metal.

※3 length of the 100m, 0.05 or less

※4 Points from the crank web of 4mm

※5 Flutter, irregular noise generated

-４４-


9-2 Tightening Torques

Tightening Item Thread size

(mm)

Tightening Torque

N・m (kgｆ・cm)

Engine

Spark Plug M14S×1.25 15～22 (150～220)

Muffler M5×20 7～9 (70～90)

Diffuser M4×8 (Reference) 2～3 (20～30)

Cylinder M5×20 6～8 (60～80)

Cylinder Plate M5×8 3～5 (30～50)

Crankcase M5×20 6～8 (60～80)

Insulator M5×20

(Apply 3M-2353 8to12mm) 5～7 (50～70)

Carburetor/ Filter Housing M5×55 (with washer) 3～5 (30～50)

Recoil Starter M5×16 3～4.5 (30～45)

Starter Pulley ━ 2.9～3.9 (30～40)

Rotor M8×1.0 (Hex nut) 10～15 (100～150)

Ratchet of Rotor M5×12 3～4 (30～40)

Ignition Coil M4×25 2.5～3.5 (25～35)

Fuel Tank 5 (1.81P-tight)×20 2～2.5 (20～25)

Engine Mount M5×22 5～7 (50～70)

Guard Net/ Volute Cover/ Volute Case/ Engine Cover 5 (1.81P-tight)×20 2～2.5 (20～25)

Fan M8×1.0 (Hex nut)

left-threading 15～18 (150～180)

Assist Handle 5 (1.81P-tight)×30 2～2.5 (20～25)

Cruise Lever M5×22 3～4.5 (30～45)

-４５-

10. Troubleshooting

10-1 Engine does not start

Remove the spark plug from the cylinder. Put the spark plug on the outside of the cylinder. Pull the recoil starter knob, and

check whether sparks occur in the spark gap or not.

Trouble Probable Cause Countermeasure

No spark in the spark plug.

Spark plug

1. Wet spark plug electrodes Make them dry.

2. Carbon deposited on the electrodes Clean or replace.

3. Smolder of the electrodes Clean or replace.

4. Insulation failure by insulator damage Replace.

5. Improper spark gap Adjust to 0.6 to 0.7mm or replace.

6. Burn-out of the electrodes Replace.

Ignition coil

1. Ignition coil inside failure Replace.

2. Air gap is not proper Adjust to 0.3mm.

3. Plug cap and cap spring are damaged Replace.

4. Damage cord sheath or disconnection Repair or replace.

Switch

1. Switch is OFF ON the switch.

2. Switch failure Replace.

3. Primary wiring ground Repair or replace.

Sparks appear in the spark plug.

Compression and fueling are normal

1. Over sucking of fuel Drain excess fuel.

2. Too rich fuel Adjust or replace carburetor.

3. Overflow Adjust or replace carburetor.

4. Clogging of the pre-filter and felt filter

Pre-filter Wash with hot water containing neutral detergent and dry.

Felt filter Clean with air blow or replace.

5. Incorrect fuel Change with proper fuel.

Fueling normal but poor compression

1. Spark plug is loosened Retighten.

2. Cylinder wall and piston ring are worn or damaged Replace.

3. Gas leakage from cylinder and crankcase Replace gasket and reassemble.

No fuel supply

1. Carburetor improper adjustment Readjust.

2. Clogged carburetor Disassemble and clean.

3. Clogged fuel filter Clean or replace.

4. Clogged or damaged fuel pipes Clean or replace.

5. Gas leakage from oil seal of the crankcase Replace.

-４６-

10. Troubleshooting

10-2 Engine stop during operation


Suddenly stopped.

1. Switch is OFF ON the switch.

2. Plug cap disconnect Connect properly.

3. Switch cord or high tension cord sheath worn out

Replace.

4. Air gap is not proper Adjust to 0.3mm

5. Ignition coil inside failure Replace.

6. Engine seizure Overhaul and replace damaged parts.

7. Clogged breather Clean.

Gradual speed reduction and stopped.

1. Lack of fuel Refill.

2. Clogged carburetor Disassemble and clean.

3. Water mixed with fuel Drain and apply new fuel.

Revolution rises suddenly and stops.

1. Lack of fuel Refill.

2. Clogged breather Clean.

3. Clogged carburetor Clean.

10-3 Engine cannot be stopped


Overheating

1. Lean fuel Adjust or replace carburetor.

2. Cooling passage clogged with dusts Clean.

3. Cylinder fin clogged with dusts Clean.

4. Improper fuel Change with proper fuel.

5. Carbon deposited inside of combustion chamber

Clean.

6. Spark plug electrode red hot Clean thoroughly and adjust spark

gap to 0.6 to 0.7mm.

Ignition coil 1. Ignition coil inside failure Replace.

Switch 1. Switch failure Replace.

2. Cord failure Replace.

-４７-

10. Troubleshooting

10-4 Lack of output power or unstable revolution


Compression is normal and no misfire.

1. Air is entering at fuel pipe joints, Secure connections.

2. Air is entering at crack or pinhole of fuel pipe.

Replace.

3. Air is entering at insulator and carburetor mounting portion

Replace gasket and retighten.

4. Air is entering at oil seal Replace.

5. Water mixed with fuel Drain/ clean and apply new fuel.

6. Piston is starting to seize Filing of seized surface with fine files or replace.

7. Muffler clogged with carbon Clean.

Overheating

1. Lean fuel Adjust or replace carburetor.

2. Cooling passage clogged with dusts Clean.

3. Cylinder fin clogged with dusts Clean.

4. Improper fuel Change with proper fuel.

5. Carbon deposited inside of combustion chamber

Clean.

6. Spark plug electrode red hot Clean thoroughly and adjust spark gap to 0.6 to 0.7mm.

Others

1. Poor fuel quality Replace with clean fuel.

2. Clogged fuel filter Clean or replace.





10-5 The amount of the wind is weak


Good compression but cannot reach the required revolutions at full throttle





3. Carburetor failure Maintenance or replace.

-４８-

10. Troubleshooting

10-6 Others


Poor fuel consumption

Clogging of the pre-filter and felt filter



hbz260ez workshop manual - zenoah

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