Makita MAKSTAR BJR240SH Manual

Models No.
Description
PRODUCT
TECHNICAL INFORMATION
CONCEPTION AND MAIN APPLICATIONS
Specification
Standard equipment
Optional accessories
< Note > The standard equipment for the tool shown may differ from country to country.
P 1 /15
BJR240
Cordless Recipro Saw
Dimensions : mm ( " )
Width ( W )
Height ( H )
Length ( L ) 469 (18-1/2)
230 (9)
255 (10)
88 (3-1/2)
L
W
H
The above model has been developed to be added to MAKSTAR
series models which are featuring New Charging System.
Other features and benefits are
* The fastest cutting speed among the cordless recipro saws
* Incredible low vibration with counterbalancing system
in its gear unit.
* Tool-less features for easy and rapid changing recipro saw blade
and for easy adjusting shoe
The variations of this model are listed below.
w /B2430
w /B2417
Battery Voltage : V
Capacity : Ah
Length of Stroke
Strokes per Minute
:spm.(min-1)High
Low
Cutting
capacity: mm (") Pipe
Wood
Electric brake
Variable switch
Speed change
Net Weight : Kg (lbs) with B2417
with B2430
32 mm (1-1/4")
0 - 2,700
0 - 2,300
24
4.4 (9.7)
4.9 (10.8)
ø 90 (3-1/2)
90 (3-1/2) in thickness
1.7 with Battery B2417 3.0 with Battery B2430
Yes
Yes
Yes (Electric 2 speed)
Model No.
BJR240SH B2417 (1.7Ah) DC24SA
Battery Charger
Q'ty of
Battery
1 pc.
BJR240SF B2430 (3.0Ah) DC24SA
1 pc.
* Recipro saw blade No.21 for steel ......................... 1 pc.
* Recipro saw blade No.22 for steel ......................... 1 pc.
* Recipro saw blade No.23 for wood ....................... 1 pc.
* Plastic carrying case ............................................... 1 pc
* Various recipro saw blades
* Charger DC24SA * Battery B2417 * Battery B2430

Features and benefits P 2 / 15
BJR240
Incredible low vibration with counterbalancing
system in its gear unit.
Model No. LoadedNo loaded
BJR240 8.7m/sec.2 10.3m/sec.2
Mod. A 11.5m/sec.2 19.8m/sec.2
Mod. B 20.4m/sec.2 20.9m/sec.2
Mod. C 14.4m/sec.2 16.2m/sec.2
Mod. D 8.1m/sec.2 9.4m/sec.2
MAKITA
Lower noise level
Comparison of the specifications
Model No. LoadedNo loaded
BJR240 82 dB 94 dB
85 dB 94 dB
85 dB
85 dB 94 dB 97 dB
95 dB91 dB
MAKITA
BJR240
MAKITA
The figures on loaded condition are based on
the cutting of chip board 19mm in thickness.
The figures on loaded condition are based on
the cutting of chip board of 19mm in thickness.
Push-in Lock System has
made it possible to install
the blade quickly.
New tool-less blade change system
Lock off push-out system has
enabled to take off the hot saw
blade of just after work, without
touching it.
Externally accessible
carbon brush
Tool-less shoe
adjustment
Electric High /Low
speed change switch
Palm fitting
soft grip
Lock off button can be
pushed from both of left
and right.
Switch with big trigger
for easy operation
24V Ni-MH Battery with
new charging system
The fastest cutting speed among
the cordless recipro saws.
See the graph in "Comparison of Products"
at page 3.
Comparison of products
Model No.
Specifications
Voltage
Tool-less
system
Length of Stroke
: mm (1-1/4")
Strokes per
Minute :spm.(min-1) High
Dimensions
including
battery
Weight including
battery :Kg (lbs)
Low
High
Low
Suppressing the vibration
Externally accessible brush
for replacing blade
for adjusting shoe
Palm fitting soft grip
Height : mm(")
Width : mm(")
Length : mm(")
32 (1-1/4)
0 - 2,700
0 - 2,300
24
Yes
Yes
Yes
Yes
Yes
469 (18-1/2)
230 (9)
*255 (10)
88 (3-1/2)
4.4 (9.7)
*4.9 (10.8)
29 (1-1/8) 28 (1-1/8) 25 (1)
0 - 2,900 0 - 2,900
0 - 2,400
24
Yes
Yes
Yes
463 (18-1/4)
232 (9-1/8)
80 (3-1/8)
3.9 (8.6)
JR180D
23 (7/8)
0 - 2,700
18
No No
No Yes
No
Yes
Yes
NoYes
Yes
Yes
No
447 (17-5/8)
206 (8-7/8)
95 (3-3/4)
3.5 (7.7)
32 (1-1/4)
19 (3/4)
0 - 2,300 0 - 2,600
24 24 19.2
No No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
495 (19-1/2)
213 (8-3/8)
76 (3)
448 (17-5/8)
240 (9-1/2)
83 (3-1/8)
3.9 (8.6) 4.3 (9.5)
393 (15-1/2)
202 (8)
76 (3)
4.5 (9.9)
*255 (10) and *4.9 (10.8) are the data when battery B2430 is attached.
Competitor A
Competitor B
Competitor C
Competitor D
Mod. A
Mod. B
Mod. C
Mod. D
Mod. D
Competitor A
Competitor B
Competitor C
Competitor D
Mod. A
Competitor
A Competitor B Competitor C Competitor D
Mod. B Mod. C

Comparison of products P 3 / 15
Comparison of the cuting speed Comparison of the working amount
per one full charged battery pack
Testing conditions
Material : Spruce (Wood) 2" x 10"
Pressure load ; 5 kg.f
Testing conditions
Material : Spruce (Wood) 2" x 10"
Pressure load ; 7 kg.f
Testing conditions
Material : Steel Pipe ø 1"
Pressure load ; 5 kg.f
MAKITA
BJR240
Competitor C
Model C
Model D
Competitor D
Competitor A
Model A
Competitor B
Model B
0 50 100 50 100150 150 200 250
100 100
100
165
160
100
165
160
MAKITA
BJR240
0 50 100 150
100
100
MAKITA
BJR240
0 50 100 150
100
100
100
80
105
95
95
(7.5 sec.)
(5.5 sec.)
110
105
105
95
120
120
Numbers in graph below are relative values when setting capacity of competitor A's model as 100.
(21 sec.)
50 100 150 200 250
100
50 100 150 200 250
100
110
120
80
: Amount with 1.7Ah battery B2417
: Whole amount with 3.0Ah battery B2430
: Amount with 1.7Ah battery B2417
: Whole amount with 3.0Ah battery B2430
: Amount with 1.7Ah battery B2417
: Whole amount with 3.0Ah battery B2430
120
120
110
180
210
195
with 1.7Ah battery
with 1.7Ah battery
with 1.7Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
with 2.0Ah battery
< Note > The data mentioned below may differ depending on the conditions of batteries' temperature,
room temperature, materials,etc.
27 / 47cuts
29 / 51cuts
11 / 19cuts
Competitor C
Model C
Model D
Competitor D
Competitor A
Model A
Competitor B
Model B
Competitor C
Model C
Model D
Competitor D
Competitor A
Model A
Competitor B
Model B

Repair P 4 / 15
< 1 > Lubrication
Apply MAKITA grease N No.1 to the following portions marked with black triangle to protect parts and machine
from unusual abrasion. See Fig. 1.
< 2 > Sealing
< 3 > Disassembling and assembling
Apply three bond 1215 to the following portion of gear housing cover which joins to gear housing, when assembling.
See Fig. 2.
(1) Removing shoe
Turn lever 60 (adjusting lever for shoe), and take off pan head screw M4x10. Then, lever 60 can be removed.
Take off hex bolt M8x25 (This hex bolt can be unscrewed by using lock lever as a wrench.), and inner plate.
Remove shoe by pulling out. See Fig. 3.
(2) Disassembling blade clamp section
Remove shoe as mentioned above. Pull out the blade clamp section, if it stays near gear housing.
1. Take off retaining ring S-18 with No.1R291 "Snap ring plier".
2. Take off driving sleeve, shoulder pin 5, compression spring 6,
pin 3, guide sleeve and driving sleeve guide from slider.
Apply 7g.
Slider
Apply 12g. Gear housing
Apply here three bond 1215
for sealing.
Gear housing cover
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Turn lever 60
(adjusting lever for shoe). Take off pan head screw M4x10.
<Note> Be careful, not to lose
hex nut M4 in lever 60.
Pan head screw
M4x10
Lever 60
Hex nut M4
Lock lever
Inner plate
Hex bolt M8x25
Pull out shoe.
Retaining ring S-18
Driving sleeve
Compression spring 6
Shoulder pin 5
Pin 3
Sleeve

Repair P 5 / 15
3. Sleeve is in the lock position. In order to free from lock position, pull sleeve toward the blade installing side.
(When the sleeve is free from lock, pin 3 (long) is at the position illustrated in Fig. 5.
4. Holding the top of slider with your finger, remove sleeve by pushing pin 3 (long) with a small sticker
through slider as illustrated in Fig. 6.
< Note > When removing sleeve, always hold the top of slider with your finger as illustrated in Fig. 6.
Otherwise, push plate and compression spring 2 can spring out from slider as illustrated in Fig. 6A,
and they will get lost.
After removing sleeve, take off push plate, compression spring 2 and torsion spring 17 from slider
as illustrated in Fig. 6B.
Fig. 5
Sleeve
Pin 3 (long)
Torsion spring 17
Slider
Blade installing side Gear housing side
Pull the sleeve to this
direction.
Fig. 6 Fig. 6A
Push plate
Compression spring 2
Fig. 6B
Torsion spring 17
Compression spring 2
Push plate
Sleeve
Sleeve
Pin 3
Pin 3 Sleeve
(3) Assembling blade clamp section
1. Assemble torsion spring 17 to slider. And then, set compression spring 2 into slider.
<Note> Pay attention to the position of the tail of torsion spring 17. It has to come to the right side
in the view from the side of shoe adjusting bolt M8x25, as illustrated in Fig. 7.
Torsion spring 17
Slider
The tail of
torsion spring 17
Compression spring 2
Threaded hole for hex bolt M8x25
Fig. 7

Repair P 6 / 15
2. Set sleeve to slider and turn it clockwise.
Fit sleeve with pin 3 (long) to slider as illustrated in Fig. 8.
3. Set guide sleeve to slider and insert push plate into slider as illustrated in Fig. 9. Push the push plate in the
vertical direction with saw blade, and pass pin 3 (long) through the hole of push plate as illustrated in Fig. 9A.
4. Remove guide sleeve and, push the driving sleeve toward the gear housing side turning it clockwise. Then
sleeve can be brought to the locked position with pin 3 (long). See Fig. 10 and Fig. 10A.
Pin 3 (long) Sleeve
Slider
Fig. 8
<Note> No need to fix sleeve by inserting pin 3 (long) through
slider in this stage.
Pin 3 (long) Sleeve
Slider
Guide sleeve
Guide sleeve
Push plate
Saw blade
Fig. 9
Fig. 10
Fig. 9A
Fig. 10A
Guide sleeve
Driving sleeve

Repair P 7 / 15
5. Remove driving sleeve, and assemble the following parts to slider. See Fig. 11.
(7) Driving sleeve guide,
(6) Guide sleeve
(1) Shoulder pin 5 (Apply a bit of MAKITA grease N.No.1 to shoulder pin 5, when assembling it.)
(2) Compression spring 6
(5) Pin 3 (short)
1. Remove insulation cover, shoe and blade clamp section. Refer to (1) Removing shoe and
(2) Disassembling blade clamp section.
2. Unscrew 4 pcs. of pan head screws M5x18, and separate gear housing cover from gear housing, as illustrated in
Fig. 12.
3. Take off 2 pcs. of plates by unscrewing 4 pcs. of pan head screws M5x16. Remove plane bearing 14 of motor
housing side, from slider. See Fig. 12A.
Aligning the convex portion of driving guide with the concave portions of sleeve and driving sleeve guide,
assemble driving sleeve and fasten it with retaining ring S-18. See Fig. 11A.
Torsion spring 17
Sleeve
(5)
(2)
(1)
(7)
(6)
Driving sleeve
Retaining ring S-18
Fig. 11 Fig. 11A
(3) Disassembling slider
Pan head screws
M5x18
Gear housing
cover
Gear housing
Gasket
Fig. 12 Fig. 12A
Motor housing side
Blade clamp side
Plane
bearing 14
Plane
bearing 14
Slider
Pan head screw
M5x16
Pan head screw
M5x16
Plate
Plate
< Note > Use impact driver for loosening pan head screws M5x16 which are fastening plates, because it is
difficult to loosen them with hand due to the adhesive on pan head screws M5x16.
4. Pushing slider to the motor housing side, remove it from gear housing cover. See Fig. 12A.

Repair P 8 / 15
(4) Assembling slider
< Note > Pay attention to the following matters, before assembling slider section.
a. Make sure that the following parts are already installed on gear housing cover.
* Slide plate See Fig. 13
* 2 pcs. of plates 12x16 (made of felt) on the places for plane bearings See Fig. 13.
b. Apply machine oil #120 to plates 12x16. See Fig. 13.
c. Apply a bit of MAKITA grease N.No.1 to the inside of dust seal 14 where the slider reciprocates.
d. Apply 7g of MAKITA grease N No.1 to slider. See Fig. 13A.
Plates 12x16
Slide plate
Fig. 13
Dust seal 14
Fig. 13A
Slider
Apply 7g of MAKITA grease N No.1.
1. Pass slider through plane bearing 14 from the blade clamp side as illustrated in Fig.14. And then, pass the slider
through dust seal in gear housing cover. Assemble plane bearing 14 to the motor housing side of slider as
illustrated in Fig. 14A. And fit plane bearings 14 on plates 12 x16 (made of felt) respectively.
Fig.14 Fig.14A
Plane bearing 14
Motor housing side
Blade clamp side
Motor housing side
Blade clamp side
Plane bearing 14
Slider
Slider
Plates 12 x16
< Note >
Pay attention to the assembling direction of plane bearings 14, when they are assembled to slider. See Fig. 14B
The convex portions of plane bearings have to
face to the center of slider, each other. The convex portions of plane bearings do not face to the center of slider.
Fig.14B

Repair P 9 / 15
Pan head screws M5x16
Plate
2. Fix plane bearings 14 and plates with 4 pcs. .of pan head screws M5x16 as illustrated in Fig.15.
Fig.15
(5) Assembling dust seal to gear housing cover No. 1R030
Bearing Setting Pipe
When assembling dust seal 14, apply the taper side of
No.1R030"Bearing Setting Pipe" on dust seal 14.
Assemble dust seal 14 by pressing the above bearing setting pipe
with arbor press. See Fig. 16.
(6) Disassembling gear section
Fig.16
Dust seal 14
Gear housing cover
Apply the taper side.
1. Remove insulation cover and shoe.
2. Unscrew 4 pcs. of pan head screws M5x18, and separate gear housing cover from gear housing, as illustrated in
Fig. 12 at page 7.
3. Lock crank shaft by inserting No.1R247 "Round Bar for Arbor" into the elliptic hole of counter weight.
Unscrew hex socket head bolt M6x18 to which adhesive is applied in advance, with hex wrench, or impact driver
See Fig. 17.
4. Remove crank shaft, ring 21, counter weight and plate.
Crank shaft
Counter weight
No.1R247
"Round Bar for Arbor"
Hex socket
head bolt M6x18
Fig. 17 Fig. 17A
Hex wrench Crank shaft
Needle bearing 708
Counter weight
Ring 21
Plate
< Note > Do not fasten the parts with the used pan head screws M5x16. Always use fresh adhesive ones.

Repair P 10 / 15
5. Remove guide plate by unscrewing 4 pcs. of countersunk head screws M5x12. See Fig. 17B.
6. Bearing retainer 18 and gear section (ball bearings 6001LLB and 6202LLB, gear shaft, ring 15, gear complete
and hex socket head bolt M10x18) are fastened with 4 pcs. of hex socket head bolts M5x10 from the shoe adjusting
lever side of gear housing. Unscrew these hex socket head bolts M5x10. See Fig. 17B.
7.Slightly hitting the edge of gear housing with plastic hammer , remove gear complete as illustrated in Fig. 17C.
8. Holding the flat portion of gear shaft with a wrench, unscrew hex socket head bolt M10x18. Then, gear complete
can be removed from gear shaft. See Fig. 17C.
< Note > Use impact driver for loosening countersunk head screws M5x12, because it is difficult to loosen
them with hand due to the adhesive on countersunk head screws M5x12.
< Note > Use impact driver for loosening hex socket head bolts M5x10, because it is difficult to loosen
them with hand due to the adhesive on hex socket head bolts M5x10.
< Note > Use impact driver for loosening hex socket head bolts M18x18, because it is difficult to loosen
them with hand due to the adhesive on hex socket head bolts M10x18.
Fig. 17B Fig. 17B Fig. 17C
Countersunk head
screws M5x12
Guide plate
Bottom view of gear
housing
Hex socket head
bolts M5x10.
Gear housing
Gear section
Bearing retainer
Wrench holding the flat portion
of gear shaft
Gear shaft
Hex socket head
bolt M10x18
Gear complete
Fig. 17C

Repair P 11 / 15
(7) Assembling gear section
1. Assemble gear section as illustrated in Fig. 18.
2. Assemble the gear section to gear housing with aligning the concave portion of bearing retainer 58 with the
edge of bearing setting hole of gear housing. See Fig. 19.
3. Assemble the gear section to gear housing with aligning the concave portion of bearing retainer 58 with the
edge of bearing setting hole of gear housing. See Fig. 19A.
Ball bearing
6001LLB
Ball bearing
6201LLB
Gear shaft
Gear complete
Ring 15
Bearing retainer 58
Fastening torque for
hex socket head bolt M10x18
is 15 - 20N.m.
Hex socket head
bolt M10x18
Fig. 18
Fig. 19
Concave portion of
bearing retainer 58
Edge of bearing setting
hole of gear housing
Bearing
retainer 58
Countersunk head
screws M5x12
Guide plate
Gear housing Gear housing
Crank shaft
Needle bearing 708
Counter weight
Ring 21
Plate
Fastening torque for
hex socket head bolt M6x18
is 10 - 15N.m.
< Note > Do not fasten the parts with the used adhesive hex socket bolt M10x18.
Always use the fresh adhesive one.
< Note > Do not fasten the parts with the used adhesive countersunk head screws M5x12 and hex socket
head bolt M6x18. Always use fresh adhesive ones.
Fig. 19A.
Apply 12g of MAKITA grease N.No.1
to gear complete.
Apply a bit of MAKITA grease N.No.1 to crank shaft, counter weight and plate

Repair P 12 / 15
(8) Disassembling armature
1. After removing shoe and insulation cover, remove brush holder caps and carbon brushes. And separate the gear
housing section from motor housing by unscrewing 4 pcs. of tapping screws M5x30. See Fig. 20.
(9) Assembling armature
1. Take the reverse steps of the above Figs.
Tapping screw
M5x30
Tapping screw
M5x30
Brush holder cap
Brush holder cap
Carbon brush
Carbon brush
Fig. 20
2. Remove baffle plate, and unscrew 2 pcs. of countersunk head screws M5x12, then armature can be
removed together with bearing retainer 58, from gear housing section. See Fig. 20A.
3. After taking off the stop ring E-10 of armature's gear side, remove ball bearing 6001DDW with No.1R269
" Bearing Extractor". Then, armature can be separated from bearing retainer 58.
Holding the armature body with plier, remove ball bearing 627DDW with No.1R269 "Bearing Extractor".
See Fig. 20B.
< Note > Countersunk head screws M5x12 are the adhesive screws. It is recommended to unscrew with
an impact driver.
Countersunk head
screws M5x12
Baffle plate Bearing retainer 58
Fig. 20A
Fig. 20B
Stop ring E-10 Ball bearing 6001DDW
Stop ring E-10
Flat washer 12
Bearing retainer 58
Ball bearing
627DDW Ball bearing
627DDW
No.1R269 Bearing extractor
No.1R269 Bearing Extractor
< Note > Do not fasten bearing retainer 58 with the used adhesive countersunk head screws M5x12 in the
step of Fig. 20A. Always use fresh adhesive countersunk head screws.
< Note > Be careful, not to be pinched your fingers between motor housing and gear housing section in
the step of Fig. 20, because armature is dragged strongly by magnetic force of yoke.

Repair P 13 / 15
(10) Disassembling handle section
1. Unscrewing 4 pcs. of tapping screws M4x30 and 2 pcs. of tapping screws M4x20, remove handle R
from handle L. So, the inner parts (for instance switch, terminal, etc.) can be removed. See Fig. 21.
2. Remove bumper, carbon brush and brush holder cap from motor housing. Then, brush holder can be removed.
See Fig. 22.
Tapping screws M4x30
Tapping screws M4x30
Tapping screws M4x20
Handle R
Switch
Terminal
Lock off butt
Fig. 21
Bumper
Brush holder
Brush holder cap
Carbon brush
Brush holder cap
Carbon brush
Fig. 22
(11) Note in assembling handle section
Insert leaf spring for High-Low speed change lever into the groove of handle L and insert its another end into
the groove of handle R firmly. See Fig. 23.
After assembling, check whether speed change lever can be locked by leaf spring on "L" and "H" side
respectively, when speed change lever is slid.
Fig. 23
Leaf spring
Handle L
This side has to come into
the groove of handle R.

Circuit diagram
Wiring diagram
P 14 / 15
Color index of lead wires
Black
White
Red
Orange
Brush holder
Terminal
High Low speed
change switch
FET
Left
Right
(Rear side of motor housing)
Lead holder B
Lead holder A
Rib
Lead wires from
brush holders
Pass lead wires of brush holders
through rib holding
with lead holder A and B.
Brush holder
Handle R side
Handle L side
Handle L side Handle R side

Wiring diagram P 15 /15
(In the handle R section)
Switch
Terminal
Brush holder
Electric High / Low
speed change switch
Rib
Pin
Fix lead wires
with lead holders.
* Inner wall
Pass the following lead wires
through the space between pin and rib.
* Lead wire (Red) from brush holder
* High Low speed change switch's lead wires (Black and White)
* FET's 3 lead wires (Black)
Fix Lead wires
(Black and Red) from
brush holders, with this
lead holder.
Fix FET's 3 lead
wires (Black ) with
this lead holder.
Pass lead wire (Black)
from brush holder,
through the space
between pin and
inner wall.
Wiring at the * Inner wall portion
Inner wall
Switch
FET
lead wires
High Low speed
change switch's
lead wires
(Black and White)
Handle R side
Handle L side
At the inner wall portion, set the lead
wires onto handle R in the following
order.
1. Lead wire (Black) from brush holder
2. FET lead wires
3. High Low speed change switch's
lead wires (Black and White)
4. Lead wire (Red) from brush holder
Lead wire (Red)
from Brush holder
Lead wire (Black)
from Brush holder