Makita DCS230T Manual

Continuous Rating (W)
Voltage (V) Cycle (Hz) Input Output Max. Output (W)
740
Models No.
Description
NEW TOOL
Current (A)
TECHNICAL INFORMATION
CONCEPT AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
Note: The standard equipment for the tool shown above may differ by country.
P 1 / 20
DCS230T/ PS-220TH
DCS231T/ PS-221TH
Engine Chain Saw 250mm
Primarily targeted at professionals who frequently prune
fruit trees or street trees, these new models have been developed
as "the lightest-in-the world*" top handle engine chain saws.
(*Note: according to our investigation, in the category of engine
chain saw and at the date of August, 2004)
Other benefits are:
Inertia chain brake
Automatic adjustable chain oiling
Easy start system
Idling start
DCS230T and PS-220TH feature no load speed of 11,500rpm whilst
DCS231T and PS-221TH feature 10,500rpm.
DCS230T and DCS231T are Makita brand models.
PS-220TH and PS-221TH are Dolmar brand models.
Chain blade 250mm (25AP-60E for carving bar or 91VG-40E for sprocket nose bar)
Guide bar (Carving bar or Sprocket nose bar)
Chain oil
Engine oil
Chain blade 250mm .......... 1 (25AP-60E for Carving bar or 91VG-40E for Sprocket nose bar)
Guide bar ........................... 1 (Carving bar or Sprocket nose bar)
Guide bar scabbard ............ 1
Wrench 13-16 .................... 1
250 (9-7/8)
22.2
Standard guide bar: mm (")
DCS230T
PS-220TH
DCS231T
PS-221TH
Specification
Model
Displacement: ml
11,500 10,500
No load speed: min-1=rpm
1/4
0.050Gauge (")
Chain blade
0.2Fuel tank capacity: l
0.74Max output: kw
2.5 (5.5)Power head weight: kg (lbs)
Pitch (")
Carving bar
Sprocket nose bar bar 3/8
0.050Gauge (")
Pitch (")
0.19Chain oil tank capacity: l
Dimensions: mm (")
Width (W)
Height (H)
Length (L)
215 (8-1/2)
202 (8)
242 (9-1/2)
L
H
W

[II] Disassembly/Assembly/Adjustment
1. Necessary Repairing Tools
2. Lubrication/Sealing
After you have disassembled the following parts, do lubrication or sealing as instructed below.
Needle bearing on clutch drum: Apply Makita grease N No. 2.
Spiral spring of recoil starter: Apply Makita grease N No. 2.
Engine: Apply Three bond 1215 to the contact surface between Crankcase and Cylinder.
Description Use forTool No.
Bearing Setting Tool 20-12.21R028
Retaining Ring Pliers ST-2N Disassembling/assembling kickback brake
(inertia chain brake) system
1R003
Bearing Setting Plate 12.2 Press-fitting Bearing to Crankshaft1R034
Drill Chuck Remover 111R048
Copper Round Bar 20-100 Removing Flywheel1R091
Air Tightness Tester Testing Carburetor1R127
T-type Hex Wrench 3-127 Removing/installing M4 Hex socket head bolt1R170
T-type Hex Wrench 4-130 Removing/installing M5 Hex socket head bolt1R171
1/4" Hex Shank Bit for M5 Removing Engine1R229
Bearing Extractor Removing Bearing from Crankshaft1R269
13mm Hex Socket Bit Removing/installing Clutch and Flywheel
Impact Driver (6990D, 6916D or the like)
Iron Hammer Removing Flywheel
0.3mm Thickness Gauge Fixing and adjusting Ignition coil complete
0.7mm Spark Plug Gauge Adjusting spark gap of Spark plug
2 / 20

1) Clutch can be easily removed using Impact driver without locking Spindle.
2) Do not remove Spark plug because Clutch is removed using compression resistance.
CAUTION: Be sure to turn off Engine stop switch to avoid injury from accidental engine startup.
3) Attach 13mm hex socket bit to Impact driver. Clutch is left-handed. Therefore, remove Clutch by turning the hexagonal
portion in the center of Clutch clockwise with the Impact driver. (Fig. 1)
3-1. Clutch Section
3-2. Inspection of Clutch Drum
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Fig. 6
3 / 20
1) Apply Makita grease N No. 2 to the Needle bearing on
Clutch drum, and insert Clutch drum in Crankshaft.
2) Set Flat washer 8 in place so that the chamfered side of
the washer faces the engine side. (Fig. 2)
3) Assemble Clutch to Crankshaft first by turning it
counterclockwise by hand, then turning counterclockwise
for one second with Impact driver. (Fig. 1)
1) If the sprockets are dirty or worn down, clean them or
replace Clutch drum by new one. (Fig. 3)
2) At the same time, check the drive links of saw chain
for damage or wear. And if necessary, replace them
by new ones. (Fig. 4)
3-3. Oil Pump Section
DISASSEMBLY
DISASSEMBLY
ASSEMBLY
1) Remove Worm gear by turning counterclockwise with thin screwdriver. (Fig. 5)
2) Unscrew 4x18 Tapping screw, and remove Oil pump cover and Chain slider (L).
3) Remove two M4x12 Pan head screws. While levering up Connector a little bit,
pull off Connector and Oil tube from Oil pump. Now Oil pump can removed. (Fig. 6)
Note: Be sure to replace Oil pump entirely by new one.
4) Check if Connector and Oil tube is cracked or clogged and if Spring (oil filter) is clogged. (Fig. 6)
loosen
tighten
Flat washer 8
Fig. 5
Worm gear Connector
Oil pump
Oil tube Spring
3. Disassembly/Assembly
CAUTION: Be sure to remove gasoline and saw chain from the machine for safety before repair/ maintenance!
Refer to the instruction manual for detailed information on how to remove or adjust saw chain.
IMPORTANT: When replacing Oil pump, also replace chain oil by fresh one.

3-3. Oil Pump Section (cont.)
3-4. Adjusting the Flow of Chain Oil
Fig. 10
Fig. 11
4 / 20
The flow of chain oil can be adjusted by turning the adjusting screw on the bottom of the machine using the slotted
screwdriver portion of Wrench 13-16 supplied.
Turn clockwise to increase the flow, and counterclockwise to decrease. (Fig. 8)
3-5. Ignition System
1) Fasten two M4x12 Pan head screws, first A then B so that Worm gear does not touch Oil pump. (Fig. 7)
2) Do not forget to set Flat washer 10 in place. (Fig. 7)
3) Install Oil pump cover and Worm gear, first Oil pump cover, then Worm gear.
4) After installation of Worm gear, make sure that Worm gear can be turned easily by hand.
1) Remove Plug cap from Spark plug. Then using circuit tester, check the
electrical conduction between Plug cap spring and the ground (earth)
terminal of Ignition coil complete. If the value of electrical resistance
is about 7k ohms, the conduction is normal. (Fig. 9)
2) If there is no or unstable electrical resistance, check if Plug cap spring
is properly connected with the ignition cable of Ignition coil complete.
Lubricate the inside of Plug cap using aerosol spray lubricant, and then
pull the ignition cable and Plug cap together spring out of Plug cap
using pliers. (Fig. 10)
3) Check if Plug cap spring is properly connected with the ignition cable.
If not, connect in the correct way as described below in 4).
Also check if Plug cap is cracked. If cracked, replace it by new one.
4) Install Plug cap spring on the ignition cable of Ignition coil complete
by piercing the needle portion of the spring in the center of the cable.
While taking care not to let Plug cap spring fall off the cable, grab the
cable with pliers and pull the spring back into Plug cap. (Fig. 11)
5) Check if Plug cap spring is properly connected with the ignition cable
of Ignition coil complete using circuit tester as described above in 1).
Defective connection can cause weak or no spark at Spark plug.
INSPECTION OF PLUG CAP
Fig. 8
Fig. 7
Flat washer 10
Pan head screw
M4x12 Decrease
Increase
Fig. 9
Plug cap
Ignition coil
complete
Ignition cable
Aerosol spray
lubricant
Plug cap
Plug cap spring
Plug cap
Pull with pliers.
Pierce in the center
of ignition cable.
ASSEMBLY
Ground (earth)
terminal

3-5. Ignition System (cont.)
5 / 20
3-7. Inspection/Replacement of Stop Switch
1) Remove Plug cap, and remove Spark plug with supplied Wrench 13-16.
Note: If Spark plug is wet with fuel, wipe it off with a clean cloth and
dry Spark plug with power blower.
2) Remove carbon deposits on the center electrode and the ground
electrode of Spark plug using wire brush.
3) Adjust the spark gap to 0.6-0.7mm by inserting a 0.7mm Spark plug
gauge in the spark gap. (Fig. 12)
4) Check if the spark occurs in the spark gap as described below:
Install Plug cap on Spark plug, touch the threaded portion of the plug
to the engine block, and then pull Recoil starter rope.
5) If no spark occurs, check the electrical conduction as described above
in 1) of CHECKING PLUG CAP.
And if the conduction is normal, replace Spark plug by new one and
re-check for a spark in the spark gap.
INSPECTION OF SPARK PLUG
1) Remove Top handle cover by removing four 4x18 Tapping screws.
2) Using circuit tester, check the electrical conduction between the terminals.
Stop switch is normal if the terminals are not conducted with the engine
turnded on and conducted with the engine turned off. (Fig. 10)
INSPECTION Fig. 15
Spark gap = the distance between the center
electrode and the ground electrode
Fig. 12
0.6 - 0.7mm
Center electrode
Ground electrode
3-6. Removal/Installation of Ignition Coil Complete
1) Before removing Ignition coil complete, remove Starter case, pull Plug cap off from Spark plug and pull the ground
(earth) wire off from the terminal on Ignition coil complete. (Fig. 13)
2) Remove two M4x20 Hex socket head bolts. Now Ignition coil complete can be removed. (Fig. 14)
Note: Be careful not to lose two Spacers through which the Hex socket bolts are inserted.
REMOVAL
1) Put Spacers and Ignition coil complete in place, and pretighten M4x20 Hex socket head bolts. Do not tighten the bolts
securely in this step. Insert a 0.3mm thickness gauge between Ignition coil complete and the magnet portion of Flywheel.
Ignition coil complete will stick to the magnet portion of Flywheel. Then tighten the bolts securely.
2) Remove the thickness gauge, then turn Flywheel to make sure that Ignition coil complete does not touch Flywheel.
INSTALLATION
Fig. 14Fig. 13
Ground (earth) wireGround (earth) terminal M4x20 Hex socket head bolt (2pcs)
Spacer
(2pcs)
Flywheel
Switch

3-7. Inspection/Replacement of Stop Switch (cont.)
6 / 20
3) Using circuit tester, also check the conduction between
the engine block and the terminal connector of the
ground (earth) wire of Ignition coil complete. (Fig. 16)
At the same time, check wrong wiring, loose screws,
loose connections or broken wires.
1) Disconnect lead wires from Switch. Now Switch can be
removed by pushing from the inside of Top handle cover.
2) Route the two lead wires (black and red) under the two
fuel tube. (Fig. 17)
REPLACEMENT Fig. 17
Fig. 16
Terminal connector of
the ground (earth) wire
of Ignition coil
3-8. Disassembling/Assembling Flywheel
1) Flywheel can be removed easily with Impact driver
without locking Piston as well as Clutch. (Fig. 18)
2) Do not remove Spark plug because Clutch is removed
using compression resistance.
CAUTION: Be sure to turn off Engine stop switch
to avoid injury from accidental engine startup.
3) Attach 13mm hex socket bit to Impact driver.
Then remove Hex nut M8 by turning counterclockwise
with the Impact driver. (Fig. 19)
Note: Be sure that Hex nut M8 is right-handed.
4) Remove Flywheel by hitting Crankshaft hard with Copper
round bar 20-100 (1R091) and iron hammer. (Fig. 19)
5) Two Ratchets on Flywheel can be removed by removing
M5x12 Hex socket button bolts with T-type hex wrench
3-127 (1R170).
DISASSEMBLING
1) Install two Torsion spring 15 on Flywheel as illustrated
on Flywheel, then fasten two Ratchets to Flywheel with
Hex socket button bolts. (Fig. 20)
2) Fitting the protrusion (key) on the center hole of
Flywheel to the groove in Crankshaft, assemble Flywheel
to Crankshaft.
3) Set Spring washer 8 in place, then fasten Hex nut M8 to
Crankshaft by turning clockwise for one second using
13mm hex socket bit and Impact driver.
ASSEMBLING
Fig. 18
Fig. 19
Fig. 20
Fuel tubes
Lead wires
Turn Hex nut M8
counterclockwise.
Flywheel
1R091

3-9. Replacement of Recoil Starter Rope
7 / 20
Fig. 22
Fig. 23
Fig. 25Fig. 24
1) Remove Side handle, and separate Recoil starter assembly from
the machine.
2) If Recoil starter rope is connected with both Starter knob and Reel,
pull Starter knob to draw the rope out of Starter case and cut it.
If the rope cannot be cut, pull Starter knob to draw out the rope till
Reel rotates one turn. Then hook the rope on the U-shaped notch in
Reel as illustrated in Fig. 21, and turn Reel counterclockwise till
Spiral spring is unwound enough.
CATION: Reel rotates very fast if you release Recoil starter rope
being pulled. Be very careful not to cut your hands.
3) Unscrew Set screw, and remove Cam and Torsion spring.
4) Remove Reel while pushing Spring case so that it does not get out
of place. (Fig. 22)
5) Untie the knots at Starter knob and Reel, then remove worn rope.
DISASSEMBLING
1) If Spiral spring has been removed, first put it in place.
2) Put new Recoil starter rope through Starter case. (Fig. 23)
Note: When using a commercial rope, cut it to 750mm.
3) Tie knots at Reel and Starter knob as illustrated in Fig. 24,25.
Do not forget to install Rope stopper as illustrated in Fig. 25
before tying a knot at Starter knob.
Important: Rope stopper is not reversible when assembled to
Starter knob. Be sure to put it through Recoil starter rope as
illustrated in Fig. 25.Failure to follow this instruction can result
in broken rope.
ASSEMBLING
Fig. 21
U-shaped notch
Recoil starter rope
Spring case
Reel
Reel
Push Spring case.
Rope stopper
Starter knob
Reel

3-9. Replacement of Recoil Starter Rope (cont.)
8 / 20
4) Connect Reel with Spiral spring by
turning clockwise while tilting it
as illustrated in Fig. 26.
By rotating Reel clockwise about
half a turn, Reel will move down
to touch Spring case completely,
indicating that it has been correctly
connected with Spiral spring.
Remember the point at which Reel
moved down.
CATION: No force is required to
connect Reel with Spiral spring.
Take care not to deform Spiral
spring by forcing Reel against
Spiral spring.
5) Put Torsion spring and Cam in place, and fasten them securely
with Set screw. (Fig. 27)
Important: Reel is not correctly connected with Spiral spring
if it does not turn smoothly after secure tightening of Set screw.
Reassemble Reel to Spiral spring as described above in 4).
6) Turn Reel counterclockwise to wind up Recoil starter rope.
(Fig. 28)
7) The loose portion can be eliminated from the rope by hooking
the rope on the U-shaped notch in Reel, turning Reel clockwise
two times, then removing the rope from the U-shaped notch.
(Fig. 29)
Remark:There are two points at which Reel hooks on Spiral spring.
Therefore, turn Reel so that it moves down to touch Spring case
at the same position as it did at first in 4).
Fig. 26
Spiral spring
[Start of connecting]
[Correctly connected]
Take care not to
hook this portion
on Spiral spring.
Tilt down Reel so that this portion
can be hooked on Spiral spring.
Put in place without being
caught by Spiral spring
Lift up this portion
so that it cannot
touch Spiral spring.
Hooked on
Spiral spring
Fig. 27
Fig. 28
Fig. 29
Torsion spring Cam

3-9. Replacement of Recoil Starter Rope (cont.)
9 / 20
1) Fix the straight end of Spiral spring in the small hole on Spring case
as illustrated in Fig. 30.
Then set Spiral spring in Spring case by winding up clockwise. (Fig. 31)
2) Spiral spring is factory-lubricated with red grease. However, you may use
Makita grease N No. 2 when repairing. Apply a little amount.
Fig. 30
Fig. 31
Spring case
If Spiral Spring Gets Out of Spring Case
Spiral spring
small hole
3-10. Disassembling/Assembling Carburetor
1) Remove Cleaner case cover.
2) Remove Choke lever by unscrewing PT3x10 Tapping screw using
slotted screwdriver. (Fig. 32)
3) Remove two M5x45 Pan head screws that fasten Cleaner case and
Carburetor. Then remove Cleaner case. (Fig. 33)
Note: If the pan head screws are left on Cleaner case, Cleaner case
cannot be removed. Be sure to remove the pan head screws from
Cleaner case before separating Cleaner case from the engine block.
4) Remove two tubes, then while tilting Carburetor so that it does not touch
Throttle wire, separate Carburetor from the engine block. (Fig. 34)
REMOVING FROM ENGINE BLOCK Fig. 32
Fig. 33
Fig. 34
Choke lever
slotted screwdriver
M5x45 Pan head screw
Throttle wire
Carburetor

3-10. Disassembling/Assembling Carburetor (cont.)
10/ 20
1) Remove Diaphragm cover and Diaphragm gasket set
by unscrewing four Pan head screws.
Note: If Gasket is sticking, carefully remove it
because it is easily broken.
2) Replace Metering diaphragm if it shows any sign of
wear, wrinkles, curling or tears.
3) Controller set can be removed by unscrewing
M3x4 (+) Screw. (Fig. 35)
4) Controller set includes Control lever, Inlet needle,
Spring and Hinge pin. When repairing Controller set,
replace the four parts at a time. (Fig. 35)
Fig. 35
DISASSEMBLING & CLEANING
Control lever Spring
Inlet needle
M3x4 (+) Screw
5) Before assembling Controller set, be sure to check
Inlet needle for wear or deformation. (Fig. 36)
Hinge pin
Fig. 36
6) When installing Control lever, make sure that the upper end of Spring is correctly placed over the protrusion of
Control lever. (Fig. 37)
[Inlet needle]
GOOD WORN DOWN
Use of worn-down
Inlet needle will
result in air pressure
leakage.
Fig. 37
Control lever
[WRONG]
Metering
diaphragm
Inlet needle
Control lever
[CORRECT]
[WRONG] [WRONG]
Dust or debris on the
valve seat will result in
air pressure leakage.
The upper end of Spring
is not placed over the
protrusion of Control lever.
[WRONG]

3-10. Disassembling/Assembling Carburetor (cont.)
11/ 20
7) Before removing two Pan head screws, tighten the idling screw on (A) to the full. (Fig. 38)
8) Before installing Strainer, ensure that it is not clogged with dust, dirt or debris. (Fig. 38)
9) Clean up the drainages in Carburetor first by spraying commercial carburetor cleaner and then, several minutes after,
by washing with gasoline.
3-11. Testing Air Tightness of Carburetor
Connect Air tightness tester (No.1R127) to the nipple
(the fuel suction port), and increase the pressure of the
tester up to 0.05Mpa.
Air tightness is normal if the tester keeps on indicating
0.05Mpa about ten seconds. (Fig. 40)
1) Referring to Fig. 38, assemble Carburetor.
2) Install (A) so that the choke adjuster is placed on
the opposite side to the tube ports. (Fig. 39)
Fig. 38
Throttle holder
[Exploded View of Carburetor]
Pan head screw
(2pcs)
(A)
Pan head screw
(4pcs)
Strainer
O ring 15 Controller set
Gasket
Gasket Metering
diaphragm
Pump
diaphragm
Diaphragm
cover
ASSEMBLING Fig. 39
Choke adjuster
Tube ports
Fig. 40
Air tightness tester
(1R127)
3-12. Assembling Parts in Handle
1) Hook the longer leg of Torsion spring 11 in the three protrusions on Lock-off lever. (Fig. 41)
2) Hook the other end of Torsion spring 11 on Throttle lever. (Fig. 42)
3) Insert Rod into Throttle lever as illustrated in Fig. 43.
Fig. 43Fig. 42Fig. 41
Torsion spring 11
Torsion spring 11
Lock-off lever
Throttle lever
Rod
Throttle lever

12/ 20
3-13. Routing Tubes
1) Route Tubes as illustrated in Fig. 44.
2) Install Gasoline filter on the end of
the fuel suction tube, which will be
placed in the fuel tank.
Connect Tube 3-140 with the fuel
suction tube using Tube joint. (Fig. 44)
3) On the top of Housing, route Tubes
as illustrated in Fig. 45, 46.
3-14. Removing/Disassembling/Assembling Engine Block
Fig. 46 Fig. 45
Fig. 50 Fig. 48 Fig. 49
Fig. 44
Gasoline filter
Fuel suction tube
Tube 3-140
Tube joint
Primer
pump
Top handle
[Around the fuel tank]
Fuel suction tube Fuel suction tube
Place the two tubes
parallel to one another.
Ensure that the fuel
suction tube is placed
inside.
Then insert the tubes
into the fuel tank.
[On the top of Housing]
Be sure to place the
fuel suction tube
inside so that it does
not touch the hex
socket head bolt
which will be very
hot from the heat
of the engine.
1) Proceed to disassemble the machine until the following parts are removed;
Spark plug, Clutch complete, two M4x12 Pan head screws (used for
fastening Oil pump), Exhaust muffler complete, Starter case complete,
Ignition coil complete, Flywheel, Carburetor
2) Insert T-type Hex Wrench 3-127 (No. 1R170) from the through hole near
the hole for the Carburetor fastening screw. And then loosen two M4x14
Hex socket head bolts that fasten Insulator. (Fig. 47)
3) Remove Damper spring and 4x18 Tapping screw that fastens Top handle to
Housing complete. (Fig. 48)
4) Release Top handle from Housing by pulling Air duct from the Ignition
coil installation side. (Fig. 49)
5) Raise the rear end of Top handle by pivoting on the front end, and remove
two M4x14 Hex socket head bolts that fasten Insulator.
Be careful not to lose the two bolts. (Fig. 50)
6) Using Impact driver and 1R229 (or 1R171), remove four M5x20 Hex socket head bolts from the top and the bottom of
the Engine block. Now Engine block can be removed from the left side of Housing.
REMOVAL
Fig. 47
1R170
Damper spring
Air duct

13/ 20
Fig. 52 Fig. 53
3-14. Removing/Disassembling/Assembling Engine Block (cont.)
1) Separate Crank case from Cylinder by removing four M5x20
Hex socket head bolts.
If cannot be separated because of the adhesive, remove by hitting
the both ends of Crankshaft alternately with plastic or wooden
hammer. Be careful not to let Crankshaft tilt too much at this time.
Cylinder can be damaged. (Fig. 51)
Now you can replace Oil seals on the ends of Crankshaft and two
Piston rings on Piston.
2) Remove Ball bearing 6001 using Bearing Extractor (No. 1R269). (Fig. 52)
Note: When press-fitting Ball bearing 6001, insert Drill Chuck Remover 11 (No. 1R048) between Crankshaft (R)
and (L) in order not to deform the bearing. (Fig. 53)
3) Pull off Piston clip from Piston pin while turning in the loosening
direction using pliers. (Fig. 54)
DISASSEMBLING
Fig. 51
Crankshaft
Bearing Extractor (No. 1R269)
Drill Chuck Remover 11
(No. 1R048)
Ball bearing 6001
1R028
1R048
1R034
Fig. 53
4) Push Piston pin out of Piston by pushing from the opposite side
using T-type Hex Wrench 4-130 (No. 1R171) or the like. (Fig. 55)
5) Now Needle gauge 8 can be extracted from Connecting rod for
replacement. When replacing Piston, replace two Piston clip at a time.
Fig. 55
Piston clip
Piston clip
1R171
Piston pin

14/ 20
3-14. Removing/Disassembling/Assembling Engine Block (cont.)
1) Assemble Piston so that the triangular marking on
its top is placed on the exhaust muffler installation
side (the longer Crankshaft side). (Fig. 56)
2) Piston ring is not reversible when assembled
to Piston. Adjusting the end-gap of Piston ring
fit in the groove of Piston; first the lower Piston
ring, then the upper one. (Fig. 57)
Caution:
1) Because Piston ring is easily broken, take care
not to expand excessively when installing new
one.
2) When inserting Piston into Cylinder, be very
careful with the position of the end-gap of
Piston ring, never placing Piston ring over the
knock pin. It will result in broken Piston ring
to force Piston into Cylinder with the ring
placed over the knock pin.
3) Crankshaft is not reversible when assembled to
Cylinder. Place it so that the longer shaft faces
the Exhaust muffler installation side. (Fig. 58)
4) Apply "Three bond 1215" to the matching surface
between Crankcase and Cylinder; it is enough to
apply the adhesive only to the shaded portion of
Crankcase.
And then aligning the protrusion on Crankcase
with one on Cylinder as illustrated in Fig. 59,
assemble them together.
ASSEMBLING
Fig. 56
Fig. 57
Fig. 58
Fig. 59
triangular marking
Crankshaft, longer
Knock pinPiston ring
[WRONG]
[WRONG]
[CORRECT]
Crankshaft, longer
Crankcase
Cylinder
Exhaust muffler
installation side
matching surface
to apply "Three
bond 1215"
Crankcase
Cylinder
Align these two protrusions.

15/ 20
3-15. Disassembling/Assembling Kickback Brake System
1) Release Brake band (Hand guard cover) by
pulling Front hand guard as illustrated in Fig. 60.
2) If Sprocket cover is assembled to the machine,
separate by loosening Collared hex nut M8 with
supplied Wrench 13-16.
3) Remove Spring cover and Chain slider (R) from
Sprocket cover Fig. 61.
4) Grasp the rear end of Compression spring 9
with Retaining ring pliers ST-2N (No. 1R003),
and pull it off from Link plate complete.
(Fig. 62)
Note: Use Retaining ring pliers ST-2N
(No. 1R003) when grasping or tightening parts
in the following disassembling/assembling steps.
5) Remove Compression spring 6.
DISASSEMBLING
1) Set all parts except Compression spring 9 in place of
Sprocket cover by doing the reverse of the assembling steps.
2) Grasp the rear end of Compression spring 9 with Retaining
ring pliers ST-2N (No. 1R003), and then it put through
Link plate complete while levering up Link plate complete
as illustrated in Fig. 64.
3) Put Compression spring 9 in Sprocket cover as follows;
First, compress one end of the spring with one jaw of the
pliers put in the first through hole in Link plate complete
other put around the fourth winding of the spring.
Then push down the other end of the spring. (Fig. 65)
4) Install Spring cover, and fasten Brake band (Hand guard
cover) with 4x12 Tapping screws.
Then move Front hand guard to make sure that it works
properly.
ASSEMBLING
Fig. 62
6) Grasp the Front hand guard section together
with Compression spring 9, and pull them off
from the machine. (Fig. 63)
7) When removing Brake band (Hand guard cover),
unscrew two 4x12 Tapping screws.
Fig. 63
Fig. 61Fig. 60
Front
hand guard
Chain slider (R)
1R003
Compression
spring 9
Link plate
complete
Link plate complete
Front guard
section
Fig. 64
Fig. 65
Push down
this end.
Compress this end.

16/ 20
3-16. Miscellaneous Remarks
[1] Do not reuse Gaskets between Exhaust muffler and Cylinder.
Always use new one for replacement. (Fig. 66)
4. Adjustment
See Instruction manual for adjustment of idling settings and saw chain tension.
[2] If any sawdust or debris in the saw chain tensioner in Sprocket cover,
blow it out using power blower or the like. (Fig. 67)
Fig. 67
Fig. 66

Circuit diagram
P 17/ 20
Switch
Ignition coil complete
Insulated connector
Body earth
Receptacle
Color index of lead wires' sheath
Black
Red
Insulated receptacle

P 18/ 20
Switch
Receptacle
Lead wire (black)
Lead wire (red)
Wiring diagram
Top handle cover
Connect the lead wires (red, black)
with the terminals of switch before
assembling the switch to the top
handle cover.
Switch
Top handle cover
Assemble the switch to the top handle cover
so that the rib on the top handle cover is
positioned between the terminals of the switch.
Fix the lead wires with
this lead wire holder.
Rib

P 19/ 20
Lead wires
Wiring diagram
Top handle cover
Route the lead wires through
the space (the shaded portion)
between the main housing and
the top cover.
Top cover
Main housing
Lead wires
Tubes
Pins
Body earth
Inside wall
Route the lead wires
under the tubes.
Route the lead wires
and the tubes between
the pins and the inside
wall.
Fix the tubes with
the lead wire holders.
Fix the lead wires with
the lead wire holders.

P 20/ 20
Lead wire
Wiring diagram
Baffle plate
Route the lead wire through
the space (the shaded portion)
between the main housing and
the baffle plate.
Main housing
Inside wall
Pin
Route the lead wire
under the tubes.
Route the lead wire
between the pin and
the inside wall.
Assemble the insulated receptacle
to the ignition coil complete as
illustrated here.
Fix the lead wire with
the lead wire holder.
Tube
Lead wire
Ignition coil complete