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General| Chain pitch | 3/8" |
|---|---|
| Oil Capacity | 0.2 L |
| Guide bar length (recommended) | 40 cm |
| Engine Power | 2.0 kW (2.7 bhp) |
| Displacement | 41.6 cm³ |
Explains symbols used in the manual for clarity and correct interpretation of instructions.
Details engine displacement, bore, stroke, power, speed, and clutch engagement.
Lists leakage test values for carburetor and tank vent, and fuel type.
Specifies air gap, spark plug type, and electrode gap for the ignition system.
Details oil pump type, delivery rate, and control method for chain lubrication.
Lists common clutch problems, their causes, and recommended remedies for proper function.
Addresses issues with chain wear, brake function, and chain tensioner operation.
Identifies causes for no oil, oil loss, or insufficient oil delivery in the chain lubrication system.
Lists causes and remedies for common rewind starter problems like rope issues or slow rewinding.
Covers engine running issues, misfires, and irregular sparks, linking to causes and remedies.
Addresses the condition of 'no spark' and lists potential causes and their solutions.
Details common carburetor problems like flooding, poor acceleration, and stalling, with causes and remedies.
Covers engine not idling, idle speed too high, stalling at idle, and power loss.
Addresses engine not starting, low power, erratic running, and overheating with their respective causes and solutions.
Instructions for removing and installing the chain catcher, including torque specifications.
Details the process for removing, inspecting, and installing the clutch drum, including wear checks.
Explains how to check the efficiency and proper functioning of the chain brake mechanism.
Provides step-by-step instructions for removing and installing the chain brake band.
Continues instructions for removing and installing the brake band, including specifics for different versions.
Details the process for removing, inspecting, and installing the brake lever and associated components.
Continues instructions for servicing the brake lever, including spring and pivot pin checks.
Explains how to remove, check, and install the cam lever that locks the hand guard.
Covers removal and installation of anchor pins, emphasizing proper seating and threadlocking.
Details steps for removing the side chain tensioner assembly, including spur gear and tensioner slide.
Continues the removal process for the side chain tensioner, focusing on the adjusting screw and thrust pad.
Provides instructions for servicing the front chain tensioner, including part inspection and lubrication.
Mentions that the quick chain tensioner is in the chain sprocket cover, referring to another section.
Covers removal and installation of the muffler, heat shield, gasket, and spark arresting screen.
Continues instructions for muffler installation, including heat shields, gaskets, and exhaust casing.
Explains the importance of leakage tests for oil seals, gaskets, and casting cracks affecting the engine.
Details the procedure for performing vacuum and pressure tests on the engine crankcase for leaks.
Lists steps for preparing the engine for a leakage test, including removing parts and fitting test flanges.
Describes how to perform a vacuum test to check oil seal integrity and interpret results.
Details the pressure test procedure to check crankcase airtightness and locate leaks.
Covers removing and installing oil seals on both the ignition and clutch sides of the engine.
Continues oil seal replacement, including specific tools and procedures for different sides.
Explains how to remove and install the engine shroud, including handling slotted nuts and stop buffers.
Continues shroud installation, including reflector foil and specific steps for versions with a decompression valve.
Outlines steps for removing the cylinder, including associated parts like the shroud, carburetor, and flywheel.
Details the cylinder removal process, including detaching hoses and screws, and preparing for reinstallation.
Covers installing the cylinder, including gasket alignment, piston ring compression, and sealing faces.
Provides detailed procedures for removing and installing the crankshaft, covering both clutch and ignition sides.
Details the installation of the crankshaft on the ignition side, including bearing lubrication and heat application.
Continues ignition side crankshaft installation, focusing on using tools and ensuring proper seating.
Details the installation of the crankshaft on the clutch side, including gasket placement and screw usage.
Summarizes the steps for removing and installing the crankshaft, covering both sides and tool usage.
Covers replacement of crankcase halves, bearings, and seals, and inspection for damage.
Continues crankcase inspection, cleaning sealing faces, and bearing replacement procedures.
Details oil seal and ball bearing replacement on both ignition and clutch sides of the crankcase.
Explains how to remove the piston from the connecting rod, including snap ring handling.
Details the process for installing the piston onto the connecting rod, including needle cage and snap ring procedures.
Covers checking and installing piston rings, including cleaning grooves and correct orientation.
Explains how to remove, check, and install the decompression valve, including sealing cone inspection.
States that ignition timing is fixed and not adjustable during repair work.
Describes the ignition module, its components, and electrical connections.
Details the steps for removing and installing the ignition module, including shroud and carburetor box cover removal.
Continues ignition module installation, covering boot, lead, ground wire, and retainer removal/installation.
Covers fitting the ignition module, setting the air gap using a gauge, and connecting wires.
Explains how to test the ignition module using specialized testers (ZAT 3/4) for spark generation.
Details how to remove, install, and prepare new ignition leads and spark plug boots.
Covers flywheel removal and installation, including checking for damage, key seating, and air gap setting.
Explains how to test the short circuit wire for continuity and breaks using an ohmmeter.
Details removing and installing the short circuit wire and ground wire, including wiring harness management.
Covers testing the ground wire's contact and continuity, and replacing the wiring harness if damaged.
A flowchart to diagnose engine running problems related to the ignition system, guiding through checks and remedies.
Continues the troubleshooting flowchart, guiding checks for spark, air gap, flywheel, short circuit wire, and ignition lead.
Continues the flowchart, covering switch shaft operation, spark plug boot, and finally engine running status.
Discusses common rewind starter issues like stiffness due to dirt or low temperatures, and lubrication.
Details how to remove and install the rewind starter, including fan housing and hand guard.
Covers removing and installing the pawl, including spring clip and lubrication.
Explains how to remove and install the rope rotor, including relieving spring tension and checking for wear.
Details replacing the starter rope and grip, including tying knots and fitting caps.
Describes the procedure for tensioning the rewind spring after installation.
Continues spring tensioning, explaining how to check correct tension and reduce it if necessary.
Covers removing and installing a new rewind spring, including safety precautions and lubrication.
Continues rewind spring replacement, detailing proper seating, anchor loop positioning, and spring fitting.
Details removing and installing the annular buffer on the chain catcher, including lubrication.
Explains removal and installation of the annular buffer at the clutch side of the engine housing.
Continues annular buffer service at the clutch side, covering plug removal and buffer installation.
Details removal and installation of the annular buffer on the ignition side of the crankcase.
Continues annular buffer service at the ignition side, including fitting the retaining plate and checking wiring.
Covers removing and installing the stop buffer, and checking it for damage.
Continues stop buffer service, focusing on positioning and ensuring proper seating.
Details the process for removing and installing the handlebar, including checking seating and tightening screws.
Continues handlebar service, covering wire routing and ensuring snug fit.
Explains procedures for handlebars with heating systems, including disconnecting wires and general compatibility.
Continues service for heated handlebars, detailing wire routing, connector management, and ensuring connections are covered.
Explains the different positions of the switch shaft (off, run, start) and how to move between them.
Details how to remove and install the switch shaft, including disconnecting the throttle rod and checking the shaft.
Covers removal of the air filter, screws, and handle molding, and disconnecting the throttle rod.
Continues service for throttle trigger and interlock lever, including drift usage, spring attachment, and alignment.
Continues throttle trigger and interlock lever service, focusing on engagement, spring attachment, and handle molding installation.
Continues service for throttle trigger and interlock lever, covering handle molding installation and final checks.
Explains how impurities clog the pickup body filter and how to remove and clean it.
Covers removing and installing the oil suction hose, and checking it for damage or leaks.
Details removing and installing the oil delivery hose, emphasizing the need for replacement if damaged during removal.
States that these pumps are not repairable and must be replaced if faulty, and mentions checking the worm.
Covers removing and installing the adjustable oil pump, including checking the worm, ring, washer, and oil delivery hose.
Explains the function of the tank vent valve and how to remove and install it if faulty.
Discusses the impact of dirty air filters on engine power and starting, and when to check it.
Details how to remove and install the carburetor, including air filter, fuel tank, and throttle rod disconnection.
Continues carburetor installation, covering sleeve, washer, carburetor position, impulse hose, and fuel hose connections.
Explains how to perform a leakage test on the carburetor and check the tank vent.
Details the procedure for testing the carburetor with a pump and interpreting pressure readings.
Covers removing the carburetor, disconnecting the throttle rod, and servicing internal carburetor components.
Details servicing the carburetor's end cover, gasket, diaphragm, and checking for damage or wear.
Explains how to remove, inspect, and install the inlet needle, control lever, and spring.
Covers removing and installing the fixed jet and checking it for damage.
Details removing and installing the pump diaphragm and gasket, including checking the fuel strainer.
Mentions the choke shutter is in the air filter, referring to another section.
Identifies the high speed, low speed, and idle speed screws and explains how to remove limiter caps.
Explains when a basic setting is needed and the procedure for carrying it out after removing the limiter cap.
Details the steps for performing the basic setting of the carburetor, including screw adjustments.
Continues basic setting, including using screwdrivers, checking chain tension, and air filter.
Outlines the standard setting procedure for the carburetor, including engine warm-up and running checks.
Covers removing and installing the throttle rod, including disconnecting it from the trigger.
Details removing and installing the intake manifold, emphasizing inspection for damage.
Continues intake manifold service, covering tank housing manipulation, string usage, and washer/ring fitting.
Explains how to remove and install the impulse hose, and check it for damage.
Describes how to test the tank vent by performing pressure and vacuum tests via the fuel hose.
Details the steps for testing the tank vent's function, including fuel draining and hose connection.
Covers removing and installing the tank vent, emphasizing the use of a new vent and proper seating.
Introduces fuel intake components like pickup body and suction hose, explaining their function and common issues.
Explains how impurities clog the pickup body filter and how to clean or replace it.
Details removing and installing the fuel suction hose, checking it for damage, and ensuring proper seating.
Covers removing and installing the tank housing, including handling mounting screws and annular buffers.
Describes how the heating element is supplied with power and controlled by the thermostat.
Explains how to test the complete carburetor heating system, including temperature considerations.
Details testing the heating element's resistance using an ohmmeter.
Continues testing the heating element, covering connection and insulation.
Explains how to remove, install, and test the thermostatic switch.
Continues thermostatic switch service, focusing on test procedures and installation.
A flowchart to diagnose problems with the carburetor heating system based on resistance and switch tests.
Identifies common faults in the handle heating system, such as circuit breaks or short circuits, and general checks.
Continues troubleshooting by checking resistance of components and using diagnostic charts.
Details removing and installing the heater switch and its associated ground wire.
Continues heater switch service, covering grommet, connector, and positioning.
Explains how a faulty ground wire affects the heating system and how to check it.
Continues ground wire service, covering terminal positioning and ensuring connections are secure.
Details testing and replacing the heating element in the rear handle, including resistance checks.
Continues heating element installation, covering backing removal, element placement, and pressure pad fitting.
States that the front handlebar heating element is not replaceable and requires a new handlebar if faulty. Includes resistance testing.
Covers removing and installing the generator, including connector disconnection and checking for damage.
Continues generator installation, covering magnet ring inspection, centering tool usage, and wire routing.
A flowchart to diagnose handle heating and generator issues, guiding through switch, resistance, and component checks.
Continues troubleshooting, covering ground wire, handlebar heating element, and heater switch checks.
Provides a table of ohmmeter connections, resistance specifications, and fault causes for troubleshooting.
Includes circuit diagrams for carburetor/handle heating and handle heating systems.
Details removing and installing the wiring harness, including connector and tube management.
Continues wiring harness service, focusing on wire routing, insulation, and ensuring secure connections.
Continues wiring harness installation, emphasizing proper wire routing and connector securing.
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