Echo HCA-2500 Mounting instructions

HCA-250015-23C-00 1
lNTRODUCTION
We are constantly working on technical
improvement of our products. For this reason,
technical data, equipment and design are
subject to change without notice. All
specifications, illustrations and directions in
this SERVICE DATA are based on the latest
products information available at the time of
publication.
1
CONTENTS page
1 SERVICE INFORMATION ............................. 2
1-1 Specification...............................................2
1-2 Technical data ............................................3
1-3 Torque limits ...............................................4
1-4 Special repairing materials ........................4
1-5 Service limits..............................................5
1-6 Special tools...............................................6
2 EMISSION ADJUSTMENT GUIDE ...............7
2-1 General adjusting rules ..............................7
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle........................................7
2-3 Adjusting carburettor..................................9
Reference No. 15-23C-00
ISSUED: 200606
INDEX

SERVICE INFORMATION HCA-2500
2
1 SERVICE INFORMATION
1-1 Specifications
Dimensions Length mm(in) 2330 (91.7)
Width mm(in) 225 (9.3)
Height mm(in) 225 (9.3)
Dry weight kg(lb) 6.4 (14.1)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Anticlockwise as viewed from the output end
Displacement cm3(in3) 23.6 (1.440)
Bore mm(in) 34.0 (1.339)
Stroke mm(in) 26.0 (1.024)
Compression ratio 6.3
Carburettor Type Rotary type : Diaphragm, horizontal-draught, with primer (purge pump)
Model Walbro WT-424C
Venturi size-Throttle bore mm(in) 7.9 - 12.7 (0.31 - 0.5)
Ignition Type CDI (Capacitor discharge ignition) system
with electronic speed governor
Spark plug BPMR7A
Starter Type Automatic rewind
Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)
Fuel Type Premixed two-stroke fuel
Mixture ratio 50 : 1 (2 %)
Petrol Minimum 89 octane petrol (RON)
Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC
Tank capacity L (U.S.fl.oz.) 0.4 (13.5)
Clutch Type Centrifugal, 2 - shoe slide
Handle Type Front Rubber grip
Rear Rubber grip with throttle trigger
Drive shaft Type Flexible
Inner shaft: Diameter - Length mm(in) 6.15 - 1522 (0.24 - 60.0)
Housing OD -ID mm(in) 25 - 22 (0.98 - 0.87)
(Main pipe) Length mm(in) 1500 (59.0)
Gear case Reduction ratio 3.95
Gear tooth Spiral bevel
Lubrication Lithium based grease
Cutter Type Double reciprocating, double edge blade
Called Length mm(in) 450 (18)
Pitch mm(in) 35.0 (1.38)
Height mm(in) 21.0 (0.83)
Thickness mm(in) 2.5 (0.098)
Articulate adjustment 180°variable at 15°pitch + storage position
OD: Outer diameter. ID: Inner diameter.

SERVICE INFORMATIONHCA-2500 3
1-2 Technical data
Engine
Idling speed r/min 2400 - 3200
Operating speed r/min 7000 - 8000
Wide open throttle speed r/min 9000 - 10500
Clutch engagement speed r/min 3700 - 4300
Compression pressure MPa (kgf/cm2) (psi) 0.94 (9.6) (136)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1500 r/min kV 15
Primay coil resistance Ω200 - 400
Secondary coil resistance kΩ1.3 - 1.8
Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)
Ignition timing at 3000 r/min °BTDC 29
at 8000 r/min °BTDC 28
at 9000 r/min °BTDC 12
Carburettor
Idle adjust screw initial setting turn in* 1 1/2
L mixture needle initial setting turn back 2 1/4
Hmixture needle initial setting turn back 3 1/4
Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 1.65 (0.065) lower than diaphragm seat
BTDC: Before top dead centre.
* Set idle speed screw to contact throttle plate before initial setting.

SERVICE INFORMATION HCA-2500
4
1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter Pawl carrier M 8 80 - 100 8 - 10 70 - 85
system Starter case M 4* 22 - 28 2.2 - 2.8 19 - 24
Ignition Ignition coil (CDI module) M 4* 38 - 55 3.8 - 5.5 35 - 50
system Spark plug M 14 150 - 170 15 - 17 130 - 150
Fan cover M 4* 38 - 55 3.8 - 5.5 35 - 50
Fuel Carburettor insulator M 5* 30 - 40 3 - 4 26 - 35
system Carburettor M 5 35 - 45 3.5 - 4.5 30 - 40
Throttle wire housing nut M 6 6 - 10 0.6 - 1.0 5 - 9
Fuel tank M 5* 27 - 32 2.7 - 3.2 23 - 28
Clutch Clutch hub M 8 180 - 200 18 - 20 155 - 175
Engine Crankcase M 5 75 - 85 7.5 - 8.5 65 - 75
Cylinder M 5 75 - 85 7.5 - 8.5 65 - 75
Cylinder cover M 4* 35 - 45 3.5 - 4.5 30 - 40
Muffler M 5 55 - 65 5.5 - 6.5 50 - 55
Top guard M 5* 25 - 35 2.5 - 3.5 22 - 30
Regular bolt, nut and screw M 3 6 - 10 0.6 - 1.0 5 - 9
M4 15 - 25 1.5 - 2.5 13 - 22
M 5 25 - 45 2.5 - 4.5 22 - 40
M 6 45 - 75 4.5 - 7.5 40 - 65
M 8 110 - 150 11 - 15 95 - 130
M 10 210 - 300 21 - 30 180 - 260
* Apply thread locking sealant. (See below)
1-4 Special repairing materials
Material Location Remarks
Grease Drive shaft
Gear case
Rewind spring Lithium based grease
Starter center post
Thread locking sealant Starter case
Ignition coil
Fan cover
Carburettor insulators Loctite #222, ThreeBond 1342 or equivalent
Fuel tank
Cylinder cover
Top guard
Latch Loctite #675 or equivalent
PTO shaft

SERVICE INFORMATIONHCA-2500 5
5K193 5K228 5K229 5K230
5K231 5K016 5K042 5K194
012345678910 11 12
0510
5K171 5K232
1-5 Service limits
ABCD
EFGH
KL
Description mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 33.91 (1.335)
C Piston pin bore Max. 8.030 (0.3161)
D Piston ring groove Max. 1.6 (0.063)
E Piston ring side clearance Max. 0.1 (0.004)
F Piston pin outer diameter Min. 7.970 (0.3138)
G Piston ring width Min. 1.45 (0.057)
H Piston ring end gap Max. 0.5 (0.02)
K Crankshaft runout Max. 0.05 (0.002)
L Clutch drum bore Max. 51.5 (2.03)

SERVICE INFORMATION HCA-2500
6
a
20
20
40
40
60
60
80
80
120
120
140
140
160
160
180
180
20
20
100
100
91019
Ignition Air Gap Gauge
#.014 = .35mm
P/N 91004
Key Part Number Description Used for:
1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor
2 363018-00310 Washer Installing crankcase oil seal of starter side
3 433019-12330 Flange nut Removing magneto rotor (flywheel)
4 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4)
5 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)
6 897701-06030 Bearing wedge Removing ball bearings on crankshaft
7 897701-14732 Bearing tool Removing and installing crankcase bearings
8 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter)
9 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing
10 897712-04630 2-pin wrench Removing and installing pawl carrier
11 897714-22830 Oil seal tool Installing ball bearing in gear case
12 897714-24330 Oil seal tool Installing crankcase oil seals
13 897726-09130 Oil seal tool Removing clutch drum and installing clutch drum ballbearing
14 91004 Module air gap gauge Adjusting pole shoe air gaps
15 897800-79931 Spark tester Checking ignition system
16 897803-30132 Pressure tester Checking carburettor and crankcase leakages
17 897835-16131 Pressure connector Checking crankcase and cylinder leakages
18 900100-08008 Bolt Removing magneto rotor (flywheel)
19 91007 Compression gauge Measuring cylinder compression
20 91019 Limiter cap tool Removing and installing limiter cap
1-6 Special tools
14: a=3mm
5 : a=4mm
236
78 910
11 12 14 15
16 18
17 20
19
13

SERVICE INFORMATIONHCA-2500 7
2 EMISSION ADJUSTMENT GUIDE
2-1 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 filter element must be clean and properly installed.
3. The muffler exhaust port must be clear of carbon.
4. The fuel lines, tank vent and fuel filter are in good condition and clear of debris.
5. The fuel is fresh ( > 89 octane : RON) and properly mixed at 50 : 1 with “ISO L-EGD”or “JASO FC”2-
stroke oil.
6. The gear case assembly with blade set adjusted clearance properly must be installed for proper engine
loading.
B. Set L and H mixture needles with limiter caps anticlockwise to rich side stop. Start and run engine for 2
minutes alternating engine speed between WOT and idle every 5 seconds. Adjust idle adjust screw to 2800
+/- 300 r/min.Adjust H mixture needle with limiter cap to 10000 +/- 500 r/min. If engine does not run correctly
after this adjustment, proceed to the next step (2-2).
C. After adjusting carburettor according to the steps 2-2 and 2-3, the limiter cap(s) must be installed on L
and/or H mixture needle(s) to comply with Emission Directive.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
1. Remove cleaner lid. Turn the L and H mixture
needles anticlockwise to rich side stop and meet
limiter caps tabs (A) with locating slot (B), using 3
mm blade screw driver.
NOTE : If cap tabs (A) misalign with locating slots
(B), there is a chance to strip thread.
2. Screw left hand thread of limiter cap tool 91019
into centre hoIe of limiter cap anticlockwise until tab
of the limiter cap just come out from locating slot.
NOTE : DO NOT COMPLETELY REMOVE
LIMITER CAP FROM CARBURETOR! If the limiter
cap were pulled out completely, there is a chance
that the other mixture needle would turn and limiter
cap tab would misalign with locating slot when
screwing the limiter cap tool into centre hole of the
other limiter cap, and thread is stripped. When the
thread is stripped by limiter cap tool, screw 3 mm
wood screw in the stripped centre hole of the limiter
cap, and pull off the cap.
91019
(Continued)
H
L
(A)
(B)
(B)
(A)

SERVICE INFORMATION HCA-2500
8
3. Remove the limiter cap tool from the limiter cap
turning the tool clockwise, leaving the limiter cap in
place.
4. Screw threaded end of limiter cap tool 91019 into
centre hole of the other limiter cap anticlockwise until
the limiter cap is come out from the mixture needle
completely. Remove the limiter cap from limiter cap
tool turning clockwise. Screw thread of limiter cap
tool 91019 into centre hole of previous limiter cap to
pull out completely.
5. Turn idle adjust screw anticlockwise and set the
screw until the tip to just contact throttle plate. Then
turn idle adjust screw 1 1/2 turns clockwise. Install
removed cleaner lid.
6.Turn L and H mixture needle clockwise until lightly
seated, and then turn both mixture needles
anticlockwise following turns.
L mixture needle : 2 1/4,
H mixture needle : 3 1/4
NOTE : If needles are forced during seating, damage
to carburettor may occur.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle (continued)
91019
91019

SERVICE INFORMATIONHCA-2500 9
2-3 Adjusting carburettor
1. Start engine and warm it up alternating engine
speed between WOT and idle every 5 seconds for
1 minute.
2. Using 2.5 mm wide blade screw driver, adjust L
mixture needle to obtain maximum idle speed.
3. Set idle speed in the range of 3,400 to 3,500
r/min by turning idle adjust screw.
4. Turn L mixture needle anticlockwise to reduce
engine idle speed 700 to 800 r/min to set idle speed
in the range of 2,600 to 2,800 r/min.
NOTE : Engine speed must be allowed to stabilize
a minimum of 20 seconds after each adjustment of
L mixture needle to assure accurate tachometer
readings.
5. Turn H mixture needle anticlockwise to reduce
engine speed to approx. 9,000 r/min at WOT.
6. Turn H mixture needle clockwise to obtain 9,500
to 10,500 r/min at WOT.
NOTE : During H mixture needle adjustment, do not
run engine at high speed without load longer than
10 seconds.
7. If the engine speed at WOT is above 10,500
r/min, adjust H mixture needle anticlockwise and set
maximum engine speed at less than 10,500 r/min.
idle adjust screw
(Continued)

SERVICE INFORMATION HCA-2500
10
2-3 Adjusting carburettor (Continued)
8.After adjusting carburettor, put new limiter cap on
the other side of limiter cap tool as shown, and press
the limiter caps to the bottoms on L and H mixture
needles respectively.
NOTE : Align the limiter cap’s tabs (A) with locating
slots (B) in extended housing of carburettor.
IMPORTANT : The limiter caps must be installed
L and H mixture needles to comply with
Emission Directive.
9. Start engine again and make sure engine runs
at idle speed in the range of 2,400 to 3,200 r/min
and at WOT engine speed in the range of 9,000 to
10,500 r/min. Also make sure blade would not move
at engine idle speed and suitable acceleration.
NOTE : Initial carburettor setting (Idle adjust screw,
L and H mixture needles) shown on page 3 and 8 is
to start the engine after restoration or carburettor
change. Idle adjust screw, L and H needles turn for
designated engine revolution through procedures
indicated here may vary. As long as idle and WOT
engine speed is set in given range, variance would
be ignorable.
H
L
(A)
(B)
(B)
(A)