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Model Bore Stroke Displacement Drive
nun (in.) nun (in.) cc (cu. in.) Type
2036 Turbo 38 32 36.3 Direct
(1.5) (1.26) (2.2)
2040 Turbo 40 32 40.2 Direct
(1.57) (1.26) (2.5)
Saws identified as Turbo models use Ib adjust the mixture screws,firstre- indicate air leaks, plugged passages or
the centrifugal force of the cooling air move and clean the airfilter,then rein- other problems.
moved by the fan to separates some of stall it. Start the engine and allow it to Ib remove carburetor (3—Fig. J112),
the foreign matterfi-omair de livered to run until it reaches normal operating first remove cylinder cover and clean
the carburetor intake. Larger wood temperature. If necessary, turn each of the area around the carburetor. Re-
chips and other impurities in air circu- the mixture needles clockwise until move air filter (1) and filter holder (2).
lated by the cooling fan are thrown to seated lightly, then back the needles Disconnect fuel line, throttle cable and
the outside by centriftigal force, while out (counterclockwise) to the initial set- choke lever. Remove the carburetor.
cleaner air nearer the fan is collected by ting so the engine can be started. When installing carburetor, be sure
a nozzle and directed toward the carbu- that throttle cable is inserted through
retor intake. Finer impurities are cap- Turn the idle speed stop screw (T) so
the engine idles at about 3,000 rpm. Ad- guide in airfilterholder (2). Tighten the
tured by the air filter. carburetor attaching screws to the
just the low-speed mixture needle (L) so
the engine idles smoothly and acceler- torque listed in the TIGHTENING
MAINTENANCE ates without hesitation. Adjust the idle TORQUE paragraph.
SPARK PLUG. Recommended speed to just slower than clutch engage-
ment speed, then recheck low-speed IGNITION. All models are equipped
spark plug is Champion RCJTY or NGK with a breakerless electronic ignition
BPMR 7A. Electrode gap should be 0.5 mixture adjustment.
system. All electronic circuitry is con-
mm (0.020 in.). The spark plug should Adjust the high-speed mixture nee- tained in a one-piece ignition mod-
be tightened to the torque listed in the dle (H) to provide the best performance ule/coil (2—Fig. J113) located outside
TIGHTENING TORQUE paragraph. while operating at maximum speed im- the fiywheel. Ignition timing is fixed
der load. Maximum no-load speed (with and not adjustable. The fiywheel at-
CARBURETOR. Walbro WT 289 bar and chain installed) is 13,000 rpm. taching nut should be tightened to the
carburetor is used. Refer to the appro- The high-speed mixture screw may be torque listed in TIGHTENING
priate Walbro section of the set slightly rich to improve perform- TORQUE paragraph.
CARBURETOR SERVICE section for ance under load. The engine may be Air gap between the legs of the mod-
service and exploded views. damaged if the high-speed screw is set ule/coil and the flywheel magnets
Initial setting of the low-speed and too lean. should be 0.3 mm (0.012 in.). When in-
high-speed mixture needles is 1-1/4 Final adjustment of the mixture nee- stalling, set the air gap between the fiy-
turns openfi-omlightly seated. Refer to dles should be within 1/4 turn of the ini-
Fig. J i l l . wheel magnets and the legs of the
tial settings. Large differences may ignition module as follows.
1-1 1/4
1-1 1/4
piston and cylinder are available for crankshaft assemblies can align the in TIGHTENING TORQUE para-
service only as a matched set and the shaft. graph.
cylinder should not be bored oversize. Remove the crankshaft and connect-
Lubricate the needle beadnjf (7—Fig. ing rod assembly as described in OIL PUMP. The automatic oil pump
J113) with engine oil before assem- PISTON, PIN, RING AND CYLINDER is driven by worm gear (13—Fig. J113)
bling. Position the piston ovei' the con- paragraphs. The crankshaft should on the crankshaft. Oil is pumped by
necting rod and needle bearing: with the turn smoothly inside main bearings plunger (14) as it rotates in the pump
arrow on piston crown toward the ex- (11) with no perceptible play or ratchet- cylinder (18). Pump output is not ad-
haust side of engine. Install retaining ing. justable for these models.
rings (6) with the opening toward the Refer to the OIL PUMP paragraph To remove the oil pump, first remove
top or bottom ofthe piston. for removal ofthe worm gear (13). The the clutch cover and chain brake (Fig.
Install the piston ring into the piston main bearings (11) and seals (12) fit J114). Remove the guide bar, chain and
groove so ends of the ring conrectly en- bores in the crankcase halves (1 and 9). clutch assembly. Unbolt and remove
gage the locating pin in the groove. The Use suitable tools to remove and install the chain guide plate (16—Fig. J113)
locating pin prevents the ringfromro- new main bearings and seals. Lubri- and the oil pump housing (15). Lift the
tating and the ends of the piston ring cate lips of seals with engine oil before pump (14 and 18) and rubber connector
must fit around this pin. installing over the crankshaft. Make (17) from the housing. Use special tool
Lubricate the connecting ix>d lower sure that mating surfaces ofthe crank- (part No. 530 03 11-36) to remove the
bearing, cylinder bore, piston and ring. case halves are properly cleaned before drive worm (13). If necessary, pull the
Make sure the ends of the piston ring assembling. oil suction pipe (19) and filter (20) from
surround the pin located in ring groove, Refer to PISTON, PIN, RING AND the oil tank.
then gently compress the ring while in- CYLINDER paragraphs for installing Clean and inspect all parts, then re-
stalling the cylinder straight over the these parts. Make sure both main bear- place any that are damaged. Use the
piston. If the cylinder is twisted, the ings (11—Fig. J113) and seals (12) are worm gear special tool to install the
ring can catch in a port and lDreak the properly seated in the upper crankcase worm gear (13) on the crankshaft. Lu-
end ofthe ring. before installing the lower half (10). bricate the oil suction pipe (19) before
Make sure both main bearings inserting in oil tank. Make sure that
(11—Fig. J113) and seals (12) are prop- CLUTCH. Refer to Fig. J114. Tb re- the suction pipe is completely seated in
erly seated in the upper crankcase. move clutch, first remove clutch cover the tank housing.
Clean the mating surfaces ofthe crank- (8), bar and chain. The clutch hub (14)
case halves, then apply a thin even coat is attached to the right end of the en- CHAIN BRAKE. The chain brake is
of sealer to the mating surfaces. Install gine crankshaft with left-hand threads designed to stop the saw chain quickly
the lower crankcase half (9), The ma- (tum clockwise to remove). Prevent the should kickback occur. The chain brake
chined surface at the side of the lower crankshaft from turning by using an is activated when the operator's hand
crankcase half, near the seal, must be appropriate piston stopper. Unscrew strikes the hand guard (3—Fig. J114).
toward the fl5rwheel side of engine. the clutch assembly from the crank- Forward movement of the hand guard
Tighten crankcase screws (S) in a cross- shaft. Special tool (part No. 530 03 disengages the trigger assembly (5) al-
ing pattern evenly to the tort^ue listed 11-12) is available from the manufac- lowing the spring (6) to tighten the
in TIGHTENING TORQUE para- turer to unscrew the clutch hub from band (7) around the clutch dmm (16).
graph. the crankshaft. The clutch drum (16) The brake is released and the mecha-
Attach the engine to the lower hous- and chain drive sprocket can be with- nism is reset by pulling back on the
ing (21) and tighten the screws (23) in a drawn aft«r the hub and shoes are re- guard. Keep the chain brake clean and
crossing pattern to the torquo listed in moved. Do not lose needle bearing (17) free of sawdust and dirt accumulation.
the TIGHTENING TORQUE para- or washer (15). Remove the clutch cover (8) to inspect
graph. The clutch shoes (12) and hub (14) and service the brake assembly. To dis-
When assembling, be sure impulse are available only as an assembly, but assemble, push hand guard (3) forward
channel (8—Fig. J112) is in place in cyl- spring (13) is available separately. Re- to release the brake. Remove hand
inder. Install a new impulse t;ube if the new clutch shoes if thickness of the guard mounting screw and drive out
old tube is lost or damaged. Slide the in- shoes is less than 1 mm (0.040 in.) at pivot sleeves (1). Separate hand guard
take connector (7) onto the cylinder, the most worn part. The inside diame- from clutch cover. Remove cover plate
then install the carburetor and air ter of the clutch drum must not exceed (9). Carefully pry spring (6) out of cover.
cleaner housing. Install muffler so that 64.4 mm (2.534 in.). Inspect all parts Drive out pin (4) and remove trigger as-
exhaust outlet is turned upwards and for wear or damage and replace as nec- sembly (5) and brake band (7).
awayfromthe cylinder. essary. Inspect all parts carefully and install
After assembly is completed, the If shoes are removed from the hub, new parts as necessary. Install a new
manufacturer recommends ttiat the bar assemble the spring and one of the brake band if any part of the band is
and chain be installed and the engine shoes on the hub. Clamp the hub, the worn to less than 0.8 mm (0.032 in.)
run 2-3 minutes. Stop the engine and one installed shoe and spring in a vise, thickness.
allow to cool, then tighter^ cylinder position the second shoe on the hub, Lubricate all pivot points lightly
screws (10—Fig. J113) again to the cor- then use a screwdriver to carefully pry when assembling. Do not allow any lu-
rect torque. the spring in position over the second bricant to get on gripping surfaces of
shoe. When assembled, the coupling for the clutch drum or brake band. No ad-
CRANKSHAFT AND CONNECT- spring (13) should be in the middle of justment of chain brake system is re-
ING ROD. The crankshaft and con- one ofthe shoes. quired.
necting rod are available only as an Grease the needle bearing in the
assembly (8—Fig. J113); individual clutch drum lightly before installing REWIND STARTER. Refer to Fig.
components are not available. A shop the drum. Install the clutch assembly, J115. The starter housing (4) can be un-
experienced in servicing built-up tightening the hub to the torque listed bolted and the assembly removed from