RedMax G9000 Instruction manual

Workshop Manual
English
G9000

English – 2
Workshop Manual
G9000
Contents
1 Introduction and safety regulations ................................2
1.1 General ......................................................................................................2
1.2 Safety..........................................................................................................2
1.3 Target group ............................................................................................2
1.4 Modications...........................................................................................2
1.5 Tools............................................................................................................2
1.6 Layout ........................................................................................................2
1.6.1 Repair of a particular system .................................................2
1.6.2 Dismantling and Assembly of the entire chainsaw......2
1.7 Numbering...............................................................................................3
1.8 General instructions..............................................................................3
1.9 Special instructions...............................................................................3
2 Symbols......................................................................................4
2.1 Symbols On The Chainsaw.................................................................4
2.2 Symbols in this Workshop manual ..................................................4
3 Technical data ..........................................................................5
4 Service tools..............................................................................7
5 Trouble shooting.....................................................................9
5.1 Trouble shooting chart ........................................................................9
5.2 Trouble shooting methods...............................................................10
6 Service data............................................................................11
7 Safety equipment ............................................................... 13
7.1 Chain brake............................................................................................13
7.1.1 Dismantling ...............................................................................13
7.1.2 Inspection...................................................................................14
7.1.3 Assembly.....................................................................................14
7.1.4 Function check .........................................................................15
7.1.5 Chain catcher ............................................................................15
7.2 Muer......................................................................................................16
7.2.1 Dismantling ...............................................................................16
7.2.2 Inspection...................................................................................16
7.2.3 Assembly.....................................................................................16
7.3 Stop switch.............................................................................................16
7.3.1 Dismantling ...............................................................................16
7.3.2 Inspection...................................................................................16
7.3.3 Assembly.....................................................................................16
7.4 Throttle lock...........................................................................................17
7.4.1 Dismantling ...............................................................................17
7.4.2 Inspection...................................................................................17
7.4.3 Assembly.....................................................................................17
8 Starter..........................................................................................................18
8.1 Starter ......................................................................................................18
8.1.1 Dismantling ...............................................................................18
8.1.2 Cleaning and inspection .......................................................18
8.1.3 Assembly.....................................................................................19
8.1.4 Checking the cord tension ...................................................19
9 Electrical system................................................................... 20
9.1 Ignition system.....................................................................................20
9.1.1 Dismantling ...............................................................................20
9.1.2 Cleaning and inspection .......................................................20
9.1.3 Assembly.....................................................................................21
9.2 Stop switch.............................................................................................21
9.3 Hand grip heater and carburettor heater 385...........................22
9.3.1 Trouble shooting......................................................................22
9.3.2 Replacing the generator .......................................................23
9.3.3 Replacing the switch ..............................................................23
9.3.4 Replacing the heating element in the tank unit...........24
9.3.5 Replacing the front hand grip.............................................24
10 Centrifugal clutch ............................................................. 25
10.1 Centrifugal clutch..............................................................................25
10.1.1 Dismantling.............................................................................25
10.1.2 Cleaning and inspection.....................................................26
10.1.3 Assembly ..................................................................................26
11 Lubrication system ........................................................... 27
11.1 Lubrication system............................................................................27
11.1.1 Dismantling.............................................................................27
11.1.2 Cleaning and inspection.....................................................28
11.1.3 Assembly ..................................................................................28
11.1.4 Adjusting the pump feed rate ..........................................28
12 Carburettor.......................................................................... 29
12.1 Carburettor..........................................................................................29
12.1.1 Description ..............................................................................29
12.1.2 Dismantling.............................................................................31
12.1.3 Cleaning and inspection.....................................................32
12.1.4 Assembly ..................................................................................33
12.1.5 Adjustment..............................................................................35
13 Tank unit ............................................................................... 37
13.1 Tank unit ...............................................................................................37
13.1.1 Dismantling.............................................................................37
13.1.2 Cleaning and inspection.....................................................38
13.1.3 Assembly ..................................................................................38
14 Anti-vibration system .................................................... 39
14.1Anti-vibration system........................................................................39
14.1.1 Dismantling.............................................................................39
14.1.2 Cleaning and inspection.....................................................39
14.1.3 Assembly ..................................................................................39
15 Piston and cylinder ........................................................... 40
15.1 Piston and Cylinder...........................................................................40
15.1.1 Dismantling.............................................................................40
15.1.2 Cleaning and inspection.....................................................40
15.1.3 Faults and causes...................................................................41
15.1.4 Assembly ..................................................................................42
16 Crankcase and crankshaft .............................................. 44
16.1 Crankcase and crankshaft ..............................................................44
16.1.1 Dismantling.............................................................................44
16.1.2 Cleaning and inspections...................................................45
16.1.3 Assembly ..................................................................................46
16.1.4 Seals ...........................................................................................48
16.1.5 Bar bolts....................................................................................48

3 – English
1 Introduction and safety regulations
1.1 General
This Workshop Manual provides a comprehensive
description of how to trouble shoot, repair and
test the chainsaw. A description of dierent safety
measures that should be taken during repair work is
also given.
1.2 Safety
Note! The section dealing with safety should
be read and understood by all who carry out
repair and service work on the chainsaw.
Warning symbols can be found in this Workshop
Manual and on the chainsaw. See page 3. A new
warning symbol must be applied as soon as pos-
sible if a warning symbol on the
chainsaw has been damaged or is missing to
ensure the greatest possible safety when using the
chainsaw.
1.3 Target group
When producing this Workshop Manual the as-
sumption has been made that personnel who use it
have general knowledge in the repair and service of
small engines.
The Workshop Manual must be read and under-
stood by personnel who are to carry out repair work
and service on the chainsaw. The Manual is also
suitable for use when training new employees.
1.4 Modications
Modications will be successively introduced on the
chainsaw during production. When these modica-
tions aect servicing and/or spare parts, separate
service information will be sent out on each occa-
sion. This means that in time this Workshop manual
will become out of date. In order to prevent this,
the Manual should be read together with all ser-
vice information issued concerning the chainsaw in
question.
1.5 Tools
Special tools must be used during specic steps. All
service tools are listed in the Workshop Manual. Us-
age is evident from respective sections.
Always use Husqvarna original:
• Spare parts
• Service tools
• Accessories
Introduction and safety regulations
1.6 Layout
This Workshop Manual can be used in two dierent
ways:
• For the repair of a particular system on the
chainsaw.
• Dismantling and Assembly of the entire chain-
saw.
1.6.1 Repair of a particular system
When a particular system on the chainsaw is to be
repaired, proceed as follows:
1. Look up the page for the system in question.
2. Carry out the sections: Dismantling, cleaning
and inspection, assembly.
1.6.2 Dismantling and Assembly
of the entire chainsaw
Proceed as follows when the entire chainsaw is to
be
dismantled and assembled:
1. Look up page 19, which deals with the Starter
and carry out the instructions under the heading
Dismantling.
2. Leaf forward in the book and carry out
Dismantling in the order given in the sections.
3. Go back the the Starter on page 1 and carry out
the instructions under Cleaning and inspection.
4. Leaf forward in the book and carry out Cleaning
and inspection in the order given in the sections.
5. Order or take out all requisite spare parts from
the stores.
6. Look up page 47 which deals with the
Crankcase and carry out the instructions under
Assembly .
7. Leaf forward in the book and carry out Assembly
in the order given in the sections.
To improve understanding some sections provide a
Description rst of the actual unit.

English – 4
1.7 Numbering
Position references to components inside the
gures are designated A, and B, etc. The gures
are number 1, 2 etc. The position references gure
numbers restart in each new
section.
1.8 General instructions
The workshop where chainsaw repairs are to be
done must be equipped with safety equipment as
set out in local regulations.
No one may repair the chainsaw unless they have
read and understood the contents of this Workshop
Manual. This Workshop Manual contains the follow-
ing warning texts in relevant places. Warning texts
are positioned before the procedures they refer to.
1.9 Special instructions
The fuel used in the chainsaw has the following haz-
ardous properties:
1. The fluid and its fumes are poisonous.
2. Can cause skin irritation.
3. Is highly inflammable.
The bar, chain and clutch cover (chain brake) must
be tted before the saw is started otherwise the
clutch can work loose and cause personal injury.
Wear ear-mus when test running.
Do not use the saw until it has been adjusted so that
the chain remains still when idling.
After test running, do not touch the muer until it
has cooled. Risk of burn injuries.
Insucient lubrication of the chain can result in the
chain breaking, which can cause serious or even
life-threatening injury.
Ensure that the spring in the starter does not y out
and cause personal injury.
If the spring tension is activated on the starter pulley
when it is to be taken up, the spring can y out and
cause personal injury.
Check that the brake is applied when removing the
pressure spring on the chain brake. Otherwise the
pressure spring can y out and cause personal
injury.
After repair, the chain brake must be checked in ac-
cordance with the instructions on page 16.
When replacing the crankshaft bearings note that
the
crankcase halves are hot. Wear protective gloves
Do not direct the compressed air jet towards the
body when using compressed air. Air can penetrate
into the blood circulation, which means mortal dan-
ger.
Introduction and safety regulations
WARNING!
The warning box warns of the
risk of personal injury if the
instructions are not followed.
NOTE!
This text warns of material damage if the
instructions are not followed.

5 – English
2.1 Symbols On The Chainsaw
The following symbols are moulded into the chain-
saw casing.
xxx Choke
Switch for hand grip heater
Fuel ller
Stop switch
Screw to adjust chain
lubrication
Chain oil ller
Electric carburettor heating
2.2 Symbols in this Workshop
manual
This symbol indicates a risk of
personal injury if instructions are
not followed.
Symbols
2 Symbols

English – 6
3 Technical data
Technical data
mpr/rewop.xaMekortSeroBtnemecalpsiD
cm3/ cubic inch Ømm/Øinch mm/inchkW/hp/ rpm
G9000 88 cm 3/5.4 55mm/2.2"3,7/1,5 4,8kW, 9600rpm
Guide bar length Chain speed at max. Chain pitch Drive link
power and 9600 rpm
hcni/mmhcni/mms/mhcni/mc
G9000 46-90/18-36 21,49,52/3,81,5/0,058
Spark plug gap Ignition systemAir gap
hcni/mmhcni/mm
G9000 0,5/0,02 FHP/CD 0.30mm/X

7 – English
Technical data
Idling speed Engage speedMax. speed Spark plug
mprmprmpr
Y7JCRnoipmahC0003100530072
Fuel tank volume Oil pump capacityOil tank volume Automatic oil pump
Litres/US pint cm 3/min Litres/US pint
seY1,1/05,0mprxx/02-49,1/09,0G9000
G9000
Weight without bar and chain Weight with bar and chain Hand grip heater Electric carburettor heater
mpr/sttaWsbl/gksbl/gk
G9000 XP 7.1/15.6 XP20" 8.5kg/18.6 65/10000 Ye s
XPG 7.3/16.1

English – 8
Service tools
4 Service tools
5421
1101
976
8
3
12
13 14

9 – English
Service tools
029181
716151
The tools listed here are service tools intended
for use on the chainsaw in question. In addition to
these tools, a standard set of hand tools is required.
Item Description Used for Order No.
1 Piston stop Locking the
crankshaft
502 54 15-01
2 Cover plate, inlet Sealing the
intake manifold
502 54 05-01
3 Cover plate,
exhaust
Sealing the
exhaust port
502 71 39-01
4 Pressure tester Produce pres-
sure when leak-
age testing
502 50 38-01
5 Extractor Dismantling the
crankshaft
502 51 61-01
6 Puller Removing bear-
ings from the
crankshaft
504 90 90-01
7 Holding tool Dismantling of
the ywheel
502 51 49-01
8 Puller Dismantling of
the ywheel
502 50 26-01
9 Piston assembly
set
Assembling the
piston
502 50 70-01
10 Assembly tool Assembling the
crankshaft
502 50 30-17
11 Extractor Removing seal on y-
wheel side
502 50
55-01
12 Feeler gauges,
air gap
Adjustment of the ignition
module
502 51
34-02
13 Tachometer Adjusting the carburettor 502 71
14-01
14 Test spark plug Checking the ignition
module
502 71
13-01
15 Clutch tool Assembling and disman-
tling of centrifugal clutch
502 52
22-01
16 Assembly bar Assembly of the spark
plug guard
502 50
06-01
17 Hook for the
fuel lter
Lifting out the fuel lter 502 50
83-01
18 Assembly
xture
Assembling the chain
saw
502 51
02-01
19 Hexagonal
screwdriver, 3
mm
For M-4 screws 502 50
86-01
19 Hexagonal
screwdriver, 4
mm
For M-5 screws 502 50
87-01
19 Hexagonal
screwdriver, 4
mm
For M-6 screws 502 50
88-01
20 Allen key, 3 mm For M-4 screws 502 50
19-01
20 Allen key, 4 mm For M-5 screws 502 50
18-01
20 Allen key, 5 mm For M-6 screws

English – 10
5.1 Trouble shooting chart
The dierent faults that can occur on the chainsaw
are divided into four groups as follows. Within each
group possible operating faults are listed to the left
while the probable fault alternatives are listed to the
right. The most likely fault is listed rst, etc.
5 Trouble shooting
Trouble shooting
Starting
1 Dicult to start Adjust the L-screw
Air lter blocked
Choke does not work
Worn choke axle
Worn choke valve
Blocked fuel lter
Blocked fuel line
Piston ring seized
Blocked impulse chan-
nel
2 Carburettor leaks
fuel
Loose or faulty fuel pipe
Hole in diaphragm
Worn needle/needle tip
Control system sticking
Control system set too
high Leaking control
system (air or fuel)
Loose cover on carburet-
tor
pump side
3 Floods when
engine is not run-
ning
Worn needle/needle tip
Control system set too
high Control system
sticking
Idling (low speed)
1 Does not idle Adjust the L-screw
Leaking intake hose (rubber)
Loose carburettor mount-
ing Loose or faulty fuel pipe
Blocked fuel lter
Blocked fuel line
Tank ventilator blocked
Throttle valve axle sti
Throttle wire sticks
Defective throttle return
spring
Bent valve axle stop
Faulty diuser jet
2 Too rich idling Adjust the L-screw
Worn needle/needle tip
Control system set too high
Worn lever arm in the control
system
Leaking diaphragm/cover
plate
Control system sticking
Idling (low speed) (continued)
1 Idles with closed
L-screw
Worn needle/needle tip
Leaking diaphragm/cover
plate Control system
sticking Worn lever arm
in the control system
Faulty diuser jet
2 Uneven idling Blocked fuel lter
Blocked fuel line
Leaking intake hose (rub-
ber)
Loose carburettor mount-
ing
Worn throttle valve axle
Loose throttle valve
screw
Worn throttle valve
Control system sticking
Leaking control system
(air or
fuel)
Worn centre knob in
control
system
Hole in diaphragm
Leaking diaphragm/cover
plate
Leaking crankcase
3 L-screw requires
constant adjust-
ment
Blocked fuel line
Control system set too
high
Control system sticking
Leaking control system
(air or
fuel)
Leaking diaphragm/cover
plate
Faulty diuser jet
Leaking crankcase
4 Too much fuel
when idling
Control system set too
high
Control system sticking
Damaged control system
Worn needle/needle tip
Leaking diaphragm/cover
plate
Incorrectly tted control
system

11 – English
Trouble shooting
High speed
Will not run at
full
throttle
Adjust H-screw
Blocked air lter
Tank ventilator blocked
Blocked fuel lter
Blocked fuel line
Loose or faulty fuel pipe
Impulse channel leaking
Blocked impulse channel
Cover on carburettor’s pump side
is loose
Faulty pump diaphragm
Leaking intake hose (rubber)
Loose carburettor mounting
Control system set too low
Damaged control system
Incorrectly tted control system
Leaking diaphragm/cover plate
Control system sticking
Blocked muer
Low power Adjust H-screw
Tank ventilator blocked
Blocked fuel lter
Impulse channel leaking
Blocked impulse channel
Cover on carburettor’s pump
side is loose
Faulty pump diaphragm
Blocked air lter
Control system sticking
Leaking control system (air or
fuel)
Control system incorrectly as-
sembled
Loose diaphragm
Hole in diaphragm
Leaking diaphragm/cover plate
Will not “four
stroke”
Tank ventilator blocked
Blocked fuel lter
Blocked fuel line
Loose or faulty fuel pipe
Impulse channel leaking
Blocked impulse channel
Cover on carburettor’s pump side
is loose
Faulty pump diaphragm
Leaking intake hose (rubber)
Loose carburettor mounting
Control system set too low
Leaking control system (air or
fuel)
Control system incorrectly as-
sembled
Loose diaphragm
Hole in diaphragm
Leaking diaphragm/cover plate
Acceleration and retardation
Does not accelerate Adjust the L-screw
Adjust the H-screw
Blocked air lter
Tank ventilator blocked
Blocked fuel lter
Blocked fuel line
Loose or faulty fuel pipe
Blocked impulse channel
Cover on carburettor’s
pump side is loose
Faulty pump diaphragm
Leaking intake hose (rub-
ber)
Loose carburettor mounting
Control system set too low
Incorrectly tted control
system
Control system sticking
Faulty diuser jet
Blocked muer
Engine stops when
throttle released
Adjust the L-screw
Adjust the H-screw
Faulty pump diaphragm
Control system set too high
Control system sticking
Faulty diuser jet
Too rich acceleration Adjust the L-screw
Adjust the H-screw
Blocked air lter
Faulty pump diaphragm
Faulty diuser jet
5.2 Trouble shooting methods
In addition to faults given in the above schematic,
trouble shooting can be carried out on a specic
component or specic chainsaw system. The dier-
ent procedures are described in respective sections
and are as follows:
1. Pressure testing the
carburettor.
See page 35.
2. Pressure testing the
crankcase and cylinder.
See page 44.
3. Pressure testing the
decompression valve.
See page 42.
4. Checking of the chain
brake.
See page 16.

English – 12
6 Service data
Service data



10
10
14
5




8

8
6
15

13 – English
Service data
4
10
4

35
4

4
4
6
6


10
15
15
1,5

English – 14
Safety equipment
7 Safety equipment
7.1 Chain brake
7.1.1 Dismantling
1. Dismantle the following parts first:
• Chain and bar. See the Operator Guide.
• Centrifugal clutch. See page 23.
2. Push the hand guard forward so that the chain
brake is on. See fig. 1.
3. Remove the hand guard, two screws. Note the
sleeve on the starter side. See fig. 2.
4. Remove the chain guide-plate (A). See fig. 1.
5. Remove the locking ring (C) with washer (D)
and lift up the clutch drum (E) with needle
bearing (F) and chain drive sprocket (G). See
fig. 3.
6. Remove the spark plug and fit the piston stop.
Remove the clutch with the clutch tool. Note –
left-hand thread. Screw in the direction of the
arrow as in fig. 4.
7. Remove the four screws (B) and the cover over
the chain brake mechanism. See fig. 1.
8. Press down the retaining bush (C fig. 5) while
releasing the lever (D fig. 5) with a screwdriver.
9. Remove the pressure spring by freeing the
back end with a screw driver. See fig. 6.
10. Remove the toggle joint (E) with attached brake
strap. See fig. 6.
11. Remove the brake strap from the toggle joint.
12. Take out the retaining bush (C) with spring. See
fig. 5.
WARNING!
Check that the brake is on.
Otherwise
the pressure spring can y out
and use personal injury.
Fig. 1
A
B
Fig. 2
Fig. 3
C
D
E
F
G
Fig. 4

English – 15
Safety equipment
7.1.2 Inspection
Clean and inspect all parts.
The thickness of the brake strap must nowhere be
less than 0.8 mm. See g. 7.
7.1.3 Assembly
Assemble the chain brake as follows:
1. Fit the toggle joint and brake strap. See fig. 7.
2. Grease the moving parts of the toggle joint (E)
and fit the unit on the chain saw. See fig. 8.
Compress the spring with special tool 502 50 67-01
and press it down with your thumb.
3. Grease and fit the lever (D). See fig. 5.
4. Grease and fit the retaining bush (C) withspring.
See fig. 5.
5. Fit the cover over the chain brake mechanism.
Four bolts (B). Tighten the bolts to 4 Nm. See
fig. 1.
6. Fit the chain guide-plate with bolt (A). See fig. 1.
7. Fit the hand guard with the sleeve on the starter
side. See fig. 2.
8. Push back the hand guard so that the chain
brake is in the off position.
9. Check that the brake strap is correctly
positioned in the recess (F) in the crankcase.
See fig. 8.
10. Fit the clutch hub on the crankshaft and tighten
with the clutch tool. Note – left-hand thread! See
fig. 9.
11. Remove the piston stop and fit the spark plug
and put on the ignition cable.
12. Grease in the needle bearing before fitting. Fit
the clutch drum (E) with needle bearing (F) and
chain drive sprocket (G). See fig. 3.
13. Fit the washer (D) and locking ring (C). See fig.
3.
14. Fit the cylinder cover, chain and bar. See
Operator Guide.
WARNING!
Ensure that the spring does not y
out and cause personal injury.
Wear protective glasses.
D
C
Fig. 5
Fig. 6
E
Fig. 7
Min. 0.8 mm
Fig. 8
C
E
F
Fig. 9

16 – English
Safety equipment
7.1.4 Function check
For this test, the engine must not be running. Check
that the chain brake cuts in as follows:
1. Hold the chain saw over a stable surface as
shown in fig. 10.The distance between the bar
and surface is given in the table below.
Bar length, L Height, H
18-20 inches
21-28 inches
50 cm
70 cm
2. Let go of the front hand grip and let the
chainsaw pivot round on the rear hand grip.
3. 3. When the bar hits the surface the chain brake
should cut in.
7.1.5 Chain catcher
Dismantle the chain and bar. See instruction book.
Inspect the chain catcher and replace it if it is dam-
aged. The bolts should be tightened to 6 Nm. See
g. 11.
Fit the chain and bar. See instruction book.
WARNING!
After repair, the chain brake must
be checked according to the
following instructions.
Fig. 10
L
H
Fig. 11

English – 17
Safety equipment
7.2 Muer
7.2.1 Dismantling
1. Remove the two lower M5 bolts and the
muffler’s two M6 bolts. See fig. 9
2. Remove the gasket and cooling plate. See fig. 9
3. If the saw is fitted with a spark-arrester, remove
it. See fig. 9.
7.2.2 Inspection
Clean all components and check the following:
1. That the spark-arrester is intact.
2. That the muffler and muffler mounting are not
cracked or otherwise defect.
3. That the gasket is undamaged.
7.2.3 Assembly
4. Clean the contact surfaces to the gasket,
cooling plate and cylinder.
5. If the saw is fitted with a spark-arrester, refit it.
See fig. 9.
6. Fit the cooling plate, gasket and muffler to the
cylinder.
Tighten the two M6 bolts to the cylinder to 14 Nm.
Tighten the four M5 bolts to 10 Nm.
7.3 Stop switch
7.3.1 Dismantling
Prise out the stop switch with a screwdriver and
detach the leads. See g. 10.
7.3.2 Inspection
Measure the resistance by connecting an ohmme-
ter to the stop switch. See g. 11. The resistance
should be as follows:
”0” pressed in - less than 0.1 ohm.
”1” pressed in - more than 1000 ohm.
7.3.3 Assembly
The symbol/stop marking should be mounted to the
rear hand grip during assembly. The earth lead is
tted in the upper or lower connection. See g. 11
WARNING!
Do not touch the muer until it
has cooled. Risk of burn injuries.
Fig. 9
Fig. 10
Fig. 11
stop

18 – English
Safety equipment
7.4 Throttle lock
7.4.1 Dismantling
1. Remove the hand grip insert (C). See fig. 12.
2. Remove the throttle lock pivot (A) with the help
of a driver. See fig. 12.
3. Press apart with a screwdriver or the like the
throttle lock/control and take out the throttle lock
from the recess in the hand grip. Now remove
the spring. See fig. 13.
4. Remove the stop switch. Press out the throttle
lever pivot (B) with a driver. See fig. 12 and 15.
5. Remove the throttle cable and lever. See fig. 15.
7.4.2 Inspection
Clean all components and check the following:
1. That the throttle cable and lever are undamaged
and run easily.
2. That the lock activation mechanism is not worn.
See fig. 13.
7.4.3 Assembly
3. Fit the throttle cable and lever. Fit the throttle
lever with pivot (B). See fig. 12 and 15.
4. Fit the spring in the recess in the throttle lock.
Hold the spring in place and locate the throttle
lock in the recess in the hand grip.
5. Fitting of the throttle lock is simplified by using a
screwdriver or the like to lock the spring. See fig.
14.
6. Fit the throttle lock pivot (A) with the help of a
driver. See fig. 12.
7. Fit the switch and hang grip insert.
Fig. 12
Fig. 15
A
B
Fig. 13
Fig. 14
B
C

English – 19
Starter
8 Starter
8.1 Starter
8.1.1 Dismantling
1. Remove the four bolts holding the starter to the
crankcase and remove the starter. See fig. 1.
2. Pull out the handle 20-30 cm and take out the
cord from the slot in the starter pulley. See fig. 2.
3. Rotate the starter pulley anticlockwise until the
tension on the pulley is released.
Clean all components and check the following:
4. Starter cord.
5. The dogs on the starter pulley.
6. That the pawls on the flywheel are intact, spring
back towards the centre and move freely.
7. Remove the central bolt and take out the
washer and starter pulley. See fig. 3.
8. If the starter cord is to be replaced, cut it off pull
out the ends from the handle and starter pulley
with pointed pliers.
9. If the spring is to be replaced, remove the old
spring.
8.1.2 Cleaning and inspection
Clean all components and check the following:
1. Starter cord.
2. The dogs on the starter pulley.
3. That the pawls on the flywheel are intact, spring
back towards the centre and move freely.
WARNING!
If the spring is tensioned on the
starter pulley it can y up and
cause personal injury.
WARNING!
If the spring is tensioned on the
starter pulley it can y up and
cause personal injury. Wear
protective glasses.
WARNING!
If the spring is tensioned on the
starter pulley it can y up and
cause personal injury. Wear
protective glasses.
Fig. 1
Fig. 2
Fig. 3

20 – English
Starter
8.1.3 Assembly
1. If a new spring is to fitted, place the new spring
with steel wire so that the end loop comes over
the peg (A) in starter pulley. See fig. 4.
2. Press down the spring in the starter pulley and
remove the wire.
3. If a new cord is to be fitted, push the free end in
the hole in the starter pulley.Take hold of the
end with pointed pliers inside the pulley and pull
up the cord. See fig. 5.
4. Grease the starter pulley bearing and spring,
and fit the pulley on the spindle.Turn gently
backwards and forwards until the spring catches
on the stop in the housing.
5. Fit the washer and bolt. See fig. 3. Tighten the
bolt to 4 Nm.
6. Pull out the cord through its hole in the housing
and fit the handle and secure it with a double
knot. See fig. 5.
7. Wind the cord onto the starter pulley and rotate
the pulley clockwise until the cord is correctly
tensioned. See below and fig. 6.
8.1.4 Checking the cord tension
A. Pull out the cord completely.
B. In this position it should be possible to turn the
pulley by hand an additional 1/2 - 3/4 turn.
1. Fit the starter on the crankcase. Tighten the
bolts to 4 Nm. See fig. 1.
Fig. 4
A
Fig. 5
Fig. 6