Zenoah BCZ2500SU Owner's manual

BCZ2500S
BCZ2500SU BCZ2500SW
OWNER/OPERATOR MANUAL
BRUSHCUTTERS
T3002-93111 (205)
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WARNING
Before using our brushcutters,
please read this manual carefully to
understand the proper use of your
unit.
WARNING
BCZ2500S DRIVE UNIT 900101 and up ENGINE UNIT 35208 and up
BCZ2500SU DRIVE UNIT 000000 and up ENGINE UNIT 35208 and up
BCZ2500SW DRIVE UNIT 100001 and up ENGINE UNIT 35208 and up
APPLICABLE SERIAL NUMBERS :
BCZ2500S
BCZ2500SU
BCZ2500SW

SAFETY FIRST
Instructions contained in warnings within this
manual marked with a symbol concern
critical points which must be taken into
consideration to prevent possible serious
bodily injury, and for this reason you are
requested to read all such instructions
carefully and follow them without fail.
■WARNINGS IN THE MANUAL
This mark indicates instructions which must be
followed in order to prevent accidents which could
lead to serious bodily injury or death.
This mark indicates instructions which must be
followed, or it leads to mechanical failure,
breakdown, or damage.
This mark indicates hints or directions useful in the
use of the product.
NOTE
IMPORTANT
WARNING
CONTENTS
1. Parts location …………………………………4
2. Specifications …………………………………4
3. Warning labels on the machine ……………5
4. Symbols on the machine ……………………6
5. For safe operation ……………………………7
6. Set up…………………………………………13
7. Fuel……………………………………………16
8. Operation ……………………………………18
9. Maintenance …………………………………21
10. Storage ………………………………………25
11. Optional blade usage ………………………26
12. Troubleshooting guide………………………31
13. Parts list………………………………………33

2. Specifications
■BCZ2500S/BCZ2500SU/BCZ2500SW
Overall size(LxWxH)
BCZ2500S/BCZ2500SU ····································· 70.5(1790)x9.8(250)x12.2(310) in(mm)
BCZ2500SW ····················································· 70.5(1790)x24.8(630)x19.1(485) in(mm)
Dry weight w/o acc.
BCZ2500S/BCZ2500SU················································· 11.7 lbs (5.3kg)/11.1 lbs (5.1kg)
BCZ2500SW ···························································································· 13.0 lbs (5.9kg)
Engine Type······················································································ Air-cooled 2-stroke gasoline
Model········································································································ Zenoah GZ25N
Displacement ······················································································· 1.6cu-in (25.4cm3)
Max. output ··································································· 1.2Hp (0.9kW)at 7500/min-1(rpm)
Idle speed··························································································3000±200/min-1(rpm)
Fuel ······················································································· Mixture(Gasoline 50 : Oil 1)
Carburetor ··················································································· Walbro Diaphragm type
Spark plug·····································································································NGK CMR7A
Fuel tank capacity·······························································································22.0 fl.oz (0.65 )
Transmission··········································································· Centrifugal clutch, Rigid driveshaft
Reduction ratio ····················································································································· 1.357
Cutting head rotating direction ················································ Counter-clockwise(Operator view)
Durability period··················································································································300hrs.
Standard Accessories
4 in. 2-line Head ········································································································ 1 pc.
Shoulder Strap ·········································································································· 1 pc.
Goggle······················································································································· 1 pc.
Tool Kit ······················································································································ 1 pc.
Specifications are subject to change without notice.
1. Parts location
BCZ2500S
BCZ2500SU BCZ2500SW
1
23
4
5
6
7
8
910
11
12
13
14
15
16
17
7
8
9
4
2
5
3
6
18
10
1. Loop handle
2. Shoulder strap hanger
3. Ignition switch
4. Throttle cable
5. Throttle lever
6. Throttle set button
7. Drive shaft housing
8. Debris guard
9. Cutting line head
10. Gear case
11. Spark arrester
12. Starter knob
13. Fuel tank
14. Primer pump
15. Choke lever
16. Air cleaner cover
17. Handle
18. Protector
❲ 4 ❳

(1)Read owner's manual before operating this machine.
(2)Wear head, eye and ear protection.
(3)Warning/Attention
(4)Keep all children, bystanders and helpers 15 meters away from the brushcutter
If warning label peel off or become soiled and impossible to read, you should contact the dealer
from which you purchased the product to order new labels and affix them in the required
location(s).
Never modify your brushcutter.
We won't warrant the machine, if you use the remodeled brushcutter or you don't observe
the proper usage written in the manual.
WARNING
IMPORTANT
3. Warning labels on the machine
❲ 5 ❳

❲ 6 ❳
For safe operation and maintenance,
symbols are carved in relief on the machine.
According to these indications, please be
careful not to take a mistake.
(a)The port to refuel the "MIX GASOLINE"
Position: FUEL TANK CAP
(b)The direction to close the choke
Position: AIR CLEANER COVER
(c) The direction to open the choke
Position: AIR CLEANER COVER
4. Symbols on the machine
IMPORTANT
ENGINE INFORMATION
THIS ENGINE MEETS U.S.EPA PH2
AND 2001 CALIFORNIA EMISSION
REGULATIONS FOR SI SORE’s
COMPLIANCE PERIOD : CATEGORYA:
ENGINE FAMILY : 1KZXS.0254QR ; EM
ENGINE DISPLACEMENT : 25.4cc
REFERTO OWNER’S MANUAL FOR MAINTE-
NANCE SPECIFICATIONS AND ADJUSTMENTS.
Ce moteur est conformc aux normcs U.S.
EPA PH2 et 2001 ainsi qu’aux autres dispositions
ultérieures de la réglementation concernant la pollution
de l’air pour les petits moteurs tout-terrain avec une
période de accordable :CATEGORYA.
Type de moteur : 1KZXS.0254QR :EM
Cylindrée du moteur : 25,4cc
Se référer au Manuel de l’utilisateur pour les
spécifications d’entretien et les réglages.
INFORMATION IMPORTANTE
CONCERNANT LE MOTEUR

❲ 7 ❳
5. For safe operation
1. Read this manual carefully until you
completely understand and follow all safety
and operating instructions.
2. Keep this manual handy so that you may refer
to it later whenever any questions arise. Also
note, if you have any questions which cannot
be answered herein, contact the dealer from
whom you purchased the product.
3. Always be sure to include this manual when
selling, lending, or otherwise transferring the
ownership of this product.
4. Never allow children or anyone unable to fully
understand the directions given in the manual
to use the machine.
■WORKING CONDITION
1. When using the product, you should wear proper
clothing and protective equipment.
(1)Helmet
(2)Ear protectors
(3)Protection goggles or face protector
(4)Thick work gloves
(5)Non-slip-sole work boots
2. And you should carry with you.
(1)Attached tools and files
(2)Properly reserved fuel
(3)Spare blade
(4)Things to notify your working area (rope,
warning signs)
(5)Whistle (for collaboration or emergency)
(6)Hatchet or saw (for removal of obstacles)
3. Do not wear loose clothing, jewelry, short
trousers, sandals, or go barefoot. Do not wear
anything which might be caught by a moving
part of the unit. Secure hair so it is above
shoulder length.
■WORKING CIRCUMSTANCE
1. Never start the engine inside a closed room or
building. Exhaust gases contain dangerous
carbon monoxide.
2. Never use the product,
a. when the ground is slippery or when you can’t
maintain a steady posture.

❲ 8 ❳
b. At night, at times of heavy fog, or at any other
times when your field of vision might be
limited and it would be difficult to gain a clear
view of the working area.
c. During rain storms, during lightning storms, at
times of strong or gale-force winds, or at any
other times when weather conditions might
make it unsafe to use the product.
■WORKING PLAN
1. You should never use the product when under
the influence of alcohol, when suffering from
exhaustion or lack of sleep, when suffering from
drowsiness as a result of having taken cold
medicine or at any other time when a possibility
exists that your judgment might be impaired or
that you might not be able to operate the product
properly and in a safe manner.
2. When planning your work schedule, allow plenty
of time to rest. Limit the amount of time over
which the product is to be used continuously to
somewhere around 30~40 minutes per session,
and take 10~20 minutes of rest between work
sessions. Also try to keep the total amount of
work performed in a single day under 2 hours or
less.
1. If you don’t observe the working time, or
working manner (See ■USING THE
PRODUCT), Repetitive Stress Injury(RSI)
could occur.
If you feel discomfort, redness and swelling
of your fingers or any other part of your
body, see a doctor before getting worse.
2. To avoid noise complaints, in general,
operate product between 8a.m. and 5p.m. on
weekdays and 9a.m. to 5p.m. weekends.
Check and follow the local regulations as to sound
level and hours of operations for the product.
NOTE
WARNING
5. For safe operation

■BEFORE STARTING THE ENGINE
1. The area within a perimeter of 50 feet (15m) of
the person using the product should be
considered a hazardous area into which no one
should enter. If necessary yellow warning rope,
warning signs should be placed around the
perimeter of the area. When work is to be
performed simultaneously by two or more
persons, care should also be taken to constantly
look around or otherwise check for the presence
and locations of other people working so as to
maintain a distance between each person
sufficient to ensure safety.
2. Check the condition of working area to avoid any
accident by hitting hidden obstacles such as
stumps, stones, cans, or broken grass.
Remove any obstacle before beginning work.
3. Inspect the entire unit for loose fasteners and
fuel leakage. Make sure that the cutting
attachment is properly installed and securely
fastened.
4. Be sure the debris guard is firmly attached in
place.
5. Always use the shoulder strap. Adjust the strap
for comfort before starting the engine. The strap
should be adjusted so the left hand can
comfortably hold the handlebar grip
approximately waist high.
■STARTING THE ENGINE
1. Keep bystanders and animals at least 50feet
(15m) away from the operating point. If you are
approached, immediately stop the engine.
2. The product is equipped with a centrifugal clutch
mechanism, so the cutting attachment begins to
rotate as soon as the engine is started by putting
the throttle into the start position. When starting
the engine, place the product onto the ground in
a flat clear area and hold it firmly in place so as
to ensure that neither the cutting part nor the
throttle come into contact with any obstacle
when the engine starts.
IMPORTANT
5. For safe operation
❲ 9 ❳

❲ 10 ❳
Never place the throttle into the high speed
position when starting the engine.
3. After starting the engine, check to make sure
that the cutting attachment stops rotating when
the throttle is moved fully back to its original
position. If it continues to rotate even after the
throttle has been moved fully back, turn off the
engine and take the unit to your authorized Red
Max servicing dealer for repair.
■USING THE PRODUCT
Cut only materials recommended by the
manufacturer. And use only for tasks explained
in the manual.
1. Grip the handles firmly with both hands using
your whole hand. Place your feet slightly apart
(slightly further apart than the width of your
shoulders) so that your weight is distributed
evenly across both legs, and always be sure to
maintain a steady, even posture while working.
2. Keep cutting attachment below waist level.
3. Maintain the speed of the engine at the level
required to perform cutting work, and never raise
the speed of the engine above the level
necessary.
4. If the unit start to shake or vibrate, turn off the
engine and check the whole unit. Do not use it
until the trouble has been properly corrected.
5. Keep all parts of your body away from rotating
cutting attachment and hot surfaces.
6. Never touch the muffler, spark plug, or other
metallic parts of the engine while the engine is in
operation or immediately after shutting down the
engine. Doing so could result in serious burns or
electrical shock.
IMPORTANT
WARNING
5. For safe operation

• IF SOMEONE COMES
1. Guard against hazardous situations at all times.
Warn adults to keep pets and children away
from the area. Be careful if you are approached.
Injury may result from flying debris.
2. If someone calls out or otherwise interrupts you
while working, always be sure to turn off the
engine before turning around.
■MAINTENANCE
1. In order to maintain your product in proper
working order, perform the maintenance and
checking operations described in the manual at
regular intervals.
2. Always be sure to turn off the engine before
performing any maintenance or checking
procedures.
The metallic parts reach high temperatures
immediately after stopping the engine.
3. When replacing the cutting attachment or any
other part, or when replacing the oil or any
lubricant, always be sure to use only RedMax
products or products which have been
certified by RedMax for use with the RedMax
product.
4. In the event that any part must be replaced or
any maintenance or repair work not described in
this manual must be performed, please contact a
representative from the store nearest RedMax
authorized servicing dealer for assistance.
5. Do not use any accessory or attachment other
than those bearing the RedMax mark and
recommended for the unit.
6. Under no circumstances should you ever take
apart the product or alter it in any way. Doing so
might result in the product becoming damaged
during operation or the product becoming unable
to operate properly.
■HANDLING FUEL
1. The engine of the RedMax product is designed
to run on a mixed fuel which contains highly
flammable gasoline. Never store cans of fuel or
WARNING
5. For safe operation
❲ 11 ❳

❲ 12 ❳
5. For safe operation
refill the tank of the unit in any place where there
is a boiler, stove, wood fire, electrical sparks,
welding sparks, or any other source of heat or
fire which might ignite the fuel.
2. Never smoke while operating the unit or refilling
its fuel tank.
3. When refilling the tank, always turn off the
engine and allow it to cool down. Take a careful
look around to make sure that there are no
sparks or open flames anywhere nearby before
refueling.
4. Wipe spilled fuel completely using a dry rag if
any fuel spillage occurs during refueling.
5. After refueling, screw the fuel cap back tightly
onto the fuel tank and then carry the unit to a
spot 10feet (3m) or more away from where it
was refueled before turning on the engine.
■TRANSPORTATION
1. When hand-carrying the product, cover over the
cutting part if necessary, lift up the product and
carry it paying attention to the blade.
2. Never transport the product over rough roads
over long distances by vehicle without removing
all fuel from the fuel tank. If doing so, fuel might
leak from the tank during transport.

■MOUNTING ENGINE (SE1)
1. Push the driveshaft housing toward the clutch
housing and rotate it by hand to check that the
driveshaft is engaged with the gears.
2. Insert the driveshaft housing into the clutch
housing until it bottoms, and align the positioning
holes on the clutch housing and the shaft tube
and install the screw. When difficult to engage,
twist the engine slightly.
3. Fasten the clamp securely with two screws.
Tighten the screws gradually by turns.
■CONNECTING THROTTLE WIRE
1. Remove the air cleaner cover.
2. Connect the end of the throttle wire to the joint
on the top of the carburetor. (SE2)
■CONNECTING SWITCH WIRES
• Connect the switch wires between the engine
and the main unit. Pair the wires of the same
color.
■INSTALLING HANDLE
• Mount the handle to the shaft tube and clamp it
at a location that is comfortable to you. (SE3)
(1)About 19 inches (48cm)
■INSTALLING DEBRIS GUARD
• Put the debris guard on the gear box, attach it
with the 4 screws and hardware provided. (SE4)
(1)debris guard
(2)plate
(3)screw
IMPORTANT
6. Set up (BCZ2500S, BCZ2500SU)
SE1
SE2
(1)
SE3
(1)
(2)
(3)
SE4
❲ 13 ❳

❲ 14 ❳
6. Set up (BCZ2500SW)
■MOUNTING ENGINE (SE5)
1. Push the driveshaft housing toward the clutch
housing and rotate it by hand to check that the
driveshaft is engaged with the gears.
2. Insert the driveshaft housing into the clutch
housing until it bottoms, and align the positioning
holes on the clutch housing and the shaft tube
and install the screw. When difficult to engage,
twist the engine slightly.
3. Fasten the clamp securely with two screws.
Tighten the screws gradually by turns.
■INSTALLING HANDLE
• Mount the handle to the shaft tube and clamp it
at a location that is comfortable to you. (SE6)
(1)About 14.5 inches (37cm)
■CONNECTING THROTTLE WIRE
1. Remove the air cleaner cover.
2. Connect the end of the throttle wire to the joint
on the top of the carburetor. (SE7)
■CONNECTING SWITCH WIRES
• Connect the switch wires between the engine
and the main unit. Pair the wires of the same
color. (SE7)
■PUTTING ON WAIST PAD
• Wrap the waist pad around the shaft tube and
the throttle wire. (SE8)
(1)Waist Pad
(2)Band
■INSTALLING DEBRIS GUARD
• Put the debris guard on the gear box, attach it
with the 4 screws and hardware provided. (SE9)
(1)Debris guard
(2)Plate
(3)Washer
(4)Screw
IMPORTANT
SE5
SE7
SE6
(1)
(2)
SE8
SE9

❲ 15 ❳
6. Set up
SE10
SE11
■INSTALLING CUTTING HEAD (SE10)
1. While locking the gear shaft, by inserting the
supplied tool into the upper holder on the gear
box, loosen and remove the hexagon nut(left-
handed)
2. Fit the holder attached to the upper holder. Then
screw in the cutting head to the gear shaft over
the holders. Hand-tighten it securely.
■BALANCE UNIT
1. Put on strap and attach unit to strap.
2. Slide clamp up or down until unit balances with
head just touching on the ground. (SE11)

❲ 16 ❳
• Gasoline is very flammable. Avoid smoking
or bringing any flame or sparks near fuel.
Make sure to stop the engine and allow it
cool before refueling the unit. Select outdoor
bare ground for fueling and move at least
3m(10ft) away from the fueling point before
starting the engine.
• The RedMax engines are lubricated by oil
specially formulated for air-cooled 2-cycle
gasoline engine use. If RedMax oil is not
available, use an anti-oxidant added quality oil
expressly labeled for air-cooled 2-cycle engine
use. (JASO FC GRADE OIL or ISO EGC
GRADE)
RECOMMENDED MIXING RATIO
GASOLINE 50:OIL 1
• Exhaust emission are controlled by the
fundamental engine parameters and
components(eq., carburation, ignition timing
and port timing) without addition of any
major hardware or the introduction of an
inert material during combustion.
• These engines are certified to operate on
unleaded gasoline.
• Make sure to use gasoline with a minimum
octane number of 90 ROZ(USA/Canada : pump
octane min.87)
• Unleaded gasoline is recommended to reduce
the contamination of the air for the sake of your
health and the environment.
• Poor quality gasolines or oils may damage
sealing rings, fuel lines or fuel tank of the
engine.
■HOW TO MIX FUEL
1. Measure out the quantities of gasoline and oil to
be mixed.
2. Put some of the gasoline into a clean, approved
fuel container.
3. Pour in all of the oil and agitate well.
4. Pour in the rest of gasoline and agitate again for
at least one minute.
5. Put a clear indication on the outside of the
WARNING
50:1 MIXING CHART
GASOLINE gal. 1 2 3 4 5
2-CYCLE OIL fl.oz 2.6 5.2 7.8 10.4 13
GASOLINE liter 1 2 3 4 5
2-CYCLE OIL ml 20 40 60 80 100
7. Fuel

container to avoid mixing up with gasoline or
other containers.
6. Indicate the contents on outside of container for
easy identification.
■FUELING THE UNIT
1. Untwist and remove the fuel cap. Rest the cap
on a dustless place.
2. Put fuel into the fuel tank to 80% of the full
capacity.
3. Fasten the fuel cap securely and wipe up any
fuel spillage around the unit.
1. Select bare ground for fueling.
2. Move at least 10 feet (3 meters) away from the
fueling point before starting the engine.
3. Stop the engine before refueling the unit.
FOR YOUR ENGINE LIFE, AVOID;
1. FUEL WITH NO OIL(RAW GASOLINE) – It will
cause severe damage to the internal engine
parts very quickly.
2. GASOHOL – It can cause deterioration of rubber
and/or plastic parts and disruption of engine
lubrication.
3. OIL FOR 4-CYCLE ENGINE USE or WATER
COOLED 2-CYCLE ENGINE USE – It can
cause spark plug fouling, exhaust port blocking,
or piston ring sticking.
4. Mixed fuels which have been left unused for
a period of one month or more may clog the
carburetor and result in the engine failing to
operate properly.
WARNING
7. Fuel
❲ 17 ❳

❲ 18 ❳
■STARTING ENGINE
The cutting head will start rotating upon the
engine starts.
1. Rest the unit on a flat, firm place. Keep the
cutting head off the ground and clear of
surrounding objects as it will start rotating upon
starting of the engine.
2. Push the primer pump several times until
overflown fuel flows out in the clear tube. (OP1)
3. Move the choke lever to the closed position.
(OP2)
4. Set the ignition switch to the “start” position.
While pulling the throttle lever, push the set
button, and release the throttle, then the throttle
lever is in to the “start” position. (OP3)
5. While holding the unit firmly, pull out the starter
rope quickly until engine fires. (OP4)
(1) choke lever (2) close (3) open
(4) ignition switch (5) start (6) stop
(7) throttle set button
• Avoid pulling the rope to its end or returning it by
releasing the knob. Such actions can cause
starter failures.
6. Move the choke lever downward to open the
choke. And restart engine. (OP2)
7. Allow the engine to warm up for a several
minutes before starting operation.
1. When restarting the engine immediately after
stopping it, leave the choke open.
2. Overchoking can make the engine hard to start
due to excess fuel. When the engine failed to
start after several attempts, open the choke and
repeat pulling the rope, or remove the spark plug
and dry it.
NOTE
IMPORTANT
WARNING
8. Operation
OP1
(1)
(2)
(3)
OP2
(4)
(7)
(5)
(6)
(4)
(7)
(5)
(6)
BCZ2500S
BCZ2500SU
BCZ2500SW
OP3
OP4

8. Operation
■STOPPING ENGINE (OP3)
1. Release the throttle lever and run the engine for
a half minute.
2. Shift the ignition switch to the STOP position.
• Except for an emergency, avoid stopping the
engine while pulling the throttle lever.
■ADJUSTING THROTTLE CABLE
• The normal play is 1 or 2mm when measured at
the carburetor side end. Readjust with the cable
adjuster as required. (OP5)
(1)cable adjuster
■ADJUSTING IDLING SPEED (OP6)
1. When the engine tends stop frequently at idling
mode, turn the adjusting screw clockwise.
2. When the cutting head keeps rotating after
releasing the trigger, turn the adjusting screw
counter-clockwise.
(1)idle adjusting screw
• Warm up the engine before adjusting the idling
speed.
■CUTTING WORK (LINE HEAD USAGE)
1. Always wear eye protection such as safety
goggles. Never lean over the rotating cutting
head. Rocks or other debris could be thrown
into eyes and face and cause serious
personal injury.
2. Keep the debris guard in place at all times
when the unit is operated.
TRIMMING GRASS AND WEEDS
• Always remember that the TIP of the line does
cutting. You will achieve better results by not
crowding the line into the cutting area. Allow the
unit to trim at its own pace.
WARNING
NOTE
IMPORTANT
(1)
OP6
.04 in
(1~2mm) (1)
OP5
❲ 19 ❳

❲ 20 ❳
1. Hold the unit so the head is off the ground and is
tilted about 20 degrees toward the sweep
direction. (OP7)
2. You can avoid thrown debris by sweeping from
your left to the right.
3. Use a slow, deliberate action to cut heavy
growth. The rate of cutting motion will depend on
the material being cut. Heavy growth will require
slower action than will light growth.
4. Never swing the unit so hard as you are in
danger of losing your balance or control of the
unit.
5. Try to control the cutting motion with the hip
rather than placing the full workload on the arm
and hands.
6. Take precautions to avoid wire, grass and dead,
dry, long-stem weeds from wrapping around the
head shaft. Such materials can stall the head
and cause the clutch to slip, resulting in damage
to the clutch system if repeated frequently.
ADJUSTING THE LINE LENGTH
• Your brushcutters is equipped with a semi- auto
type nylon line head that allows the operator to
advance the line without stopping the engine.
When the line becomes short, lightly tap the
head on the ground while running the engine at
full throttle.
• Each time the head is bumped, the line advance
about 1 inch(25.4 mm). For better effect, tap the
head on bear ground or hard soil. Avoid
bumping in thick, tall grass as the engine may
stall by overload.
8. Operation
OP7