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INTRODUCTION
We are constantly working on technical
improvement of our products. For this reason,
technical data, equipment and design are subject to
change without notice. All specifications,
illustrations and directions in this SERVICE DATA
are based on the latest products information
available at the time of publication.
CHAIN SAW
CS-3500
SERVICE DATA
1
01-34A-00 CS-3500
CONTENTS
page
1 SERVICE INFORMATION ............................ 2
1-1 Specifications ............................................ 2
1-2 Technical data .......................................... 3
1-3 Torque limits ............................................. 4
1-4 Special repairing materials ....................... 4
1-5 Service limits ............................................. 5
1-6 Special tools ............................................. 6
2. SERVICE HINT
2-1 Assembling clutch...................................... 7
Reference No. 01-34A-00
ISSUED : 199909
INDEX
1 SERVICE INFORMATION
1-1 Specifications
Dimensions Length* mm(in) 386 (15.2)
Width* mm(in) 223 (8.78)
Height mm(in) 258 (10.2)
Dry weight* kg(lb) 3.75 (8.27)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Two-piece casting, Ventilated piston
Rotation Clockwise as viewed from the output end
Displacement cm
3
(in3) 34.0 (2.075)
Bore mm(in) 38.0 (1.496)
Stroke mm(in) 30.0 (1.181)
Compression ratio 6.5
Carburettor Type Diaphragm horizontal-draught
Supplier and Model Walbro WT-504
Venturi size-Throttle bore mm(in) 11.11 - 15.85 (7/16 - 5/8)
Ignition Type CDI (Capacitor discharge ignition) system
in a single integrated piece, with electronic timing advancer
Spark plug BPMR7A, RCJ7Y
Starter Type Automatic rewind
Rope diameter x length mm(in) 3.0 x 890 (0.12 x 35.0)
Fuel Type Premixed two-stroke fuel (Refer to operator's manual.)
Tank capacity cm
3
(U.S.fl.oz.) 320 (10.8)
Clutch Type Centrifugal, 3-shoe slide
Guide bar / Saw chain lubrication type Automatic with volume adjuster
Tank capacity, oil cm
3
(U.S.fl.oz.) 180 (6.09)
Sprocket Type Spur
Number of teeth 6
Pitch in 3/8 Low profile
Guide bar Type 30RC50-3/8 35RC50-3/8 40RC50-3/8
Called length cm 30 35 40
Gauge in 0.050
Saw chain Number of drive links 47 53 58
Pitch in 3/8 Low profile
Gauge in 0.050
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SERVICE INFORMATION CS-3500
*Without guide bar and saw chain
3
SERVICE INFORMATIONCS-3500
1-2 Technical data
Engine
Idling speed rpm 2800 - 3200
Operating speed rpm 8000 - 10000
High speed (No load full throttle)* rpm 11500 - 12000
Clutch-in speed rpm 4200 - 4800
Compression pressure kgf/cm
2
(psi) 7.7 (109)
Carburettor
Idle speed screw initial setting turn in 1 3/4
L needle initial setting turns back 1 1/4
H needle initial setting turns back 1 1/8
Test pressure kgf/cm2(psi) 0.5 (7.0)
Metering lever height mm(in) 1.65 (0.065) lower than diaphragm seat
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage
at 1500 rpm
kV 18
Secondary coil resistance kΩ 1.7 - 2.2
Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)
Ignition timing °BTDC
at 1500 rpm 26.5
at 3000 rpm 26.5
at 8000 rpm 25
Chain oil discharge volume at 7000 rpm
cm
3
/min(U.S.fl.oz./min) 1.5 - 13 (0.05 - 0.45) adjustable
BTDC: Before top dead center.
*With guide bar and saw chain.
1-3 Torque limits
Descriptions Size kgf•cm N•m
Crankcase M 5 70 - 110 7 - 10
Engine mount M 5 70 - 110 7 - 10
Cylinder cover M 4* 10 - 20 1.0 - 1.9
Intake bellows M 5 30 - 45 3.0 - 4.4
Carburettor elbow M 5* 20 - 40 2.0 - 3.9
Clutch hub LM 8 300 - 400 30 - 39
Chain catcher M 5* 20 - 40 2.0 - 3.9
Flywheel M 8 200 - 240 20 - 23
Ignition coil (CDI module) M 5** 30 - 45 3.0 - 4.4
Spark plug M14 130 - 170 13 - 16
Starter pawl M 5** 30 - 45 3.0 - 4.4
Starter case M 4 15 - 25 1.5 - 2.4
Sprocket guard plate M 4* 10 - 20 1.0 - 1.9
Muffler M 5 50 - 75 4.9 - 7.3
Cushion Front handle M 4** 10 - 15 1.0 - 1.4
Engine cover front M 4* 20 - 40 2.0 - 3.9
Engine cover rear M 4 15 - 25 1.5 - 2.4
Auto-oiler M 4 15 - 25 1.5 - 2.4
Throttle latch M10 6 - 10 0.6 - 0.9
Front handle M 5* 15 - 25 1.5 - 2.4
Handle assembly M 4 12 - 18 1.2 - 1.7
M 5 20 - 35 2.0 - 3.4
M 5* 20 - 40 2.0 - 3.9
Guide bar M 6 90 - 110 9 - 10
Regular bolt, nut, M 3 6 - 10 0.6 - 0.9
and screw M 4 15 - 25 1.5 - 2.4
M 5 25 - 45 2.5 - 4.4
M 6 45 - 75 4.5 - 7.3
* Tapping screw
** Apply thread locking sealant
LM: Left-hand thread
Material Location Remarks
Adhesive Ball bearing outer / crankcase Loctite #675, RC #75 or equivalent
Grease Auto-oiler worm
Clutch needle bearing
Cushion, inside Lithium based grease
Oil seal lip
Rewind spring
Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)
Liquid gasket Crankcase seams Loctite #518 or equivalent
Thread locking sealant Ignition coil screws
Starter pawl screws Loctite #222, ThreeBond #1342, #1344
Cushion screws (Front handle) or equivalent
1-4 Special repairing materials
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SERVICE INFORMATION CS-3500
1-5 Service limits
Description mm (in)
A Cylinder bore When plating is worn and aluminum can be seen
B Piston outer diameter Min. 37.90 (1.492)
C Piston pin bore Max. 8.030 (0.3161)
D Piston ring groove Max. 1.6 (0.063)
E Piston ring side clearance Max. 0.1 (0.004)
F Piston pin outer diameter Min. 7.98 (0.3142)
G Piston ring width Min. 1.45 (0.057)
H Piston ring end gap Max. 0.5 (0.02)
K Con-rod small end bore Max. 11.025 (0.4341)
L Crankshaft runout Max. 0.05 (0.002)
M Sprocket bore Max. 13.08 (0.5150)
N Clutch drum bore Max. 61.0 (2.40)
P Sprocket wear limit Max. 0.5 (0.02)
5K177 5K083 5K084 5K081
5K082 5K016 5K025
5K174 5K181 5K097
5K178
5K173
1
23
ABCD
EFGH
KLMP
N
5
SERVICE INFORMATIONCS-3500
1-6 Special tools
1.35
0.4
1.65
1.5
a
1
5
9
13
2 : a = 4 mm
6
10
14
3
7
11
4
8
12
6
SERVICE INFORMATION CS-3500
Key Part Number Description Used for:
1 Tachometer Adjusting carburettor
2 895610-79920 L-hex. wrench(4 mm) Removing and installing hex. socket bolt (M5)
3 897501-03938 Puller Removing flywheel and auto-oiler
4 897505-16133 Clutch tool Removing and installing clutch assembly
5 897537-30130 Piston stopper Locking crankshaft rotation
6 897563-19830 Metering lever gauge Measuring metering lever height on carburettor
7 897701-02830 Bearing wedge Removing ball bearing from crankshaft
8 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter)
9 897603-23030 PTO shaft puller Removing plug on auto-oiler assembly
{Use with bolt (M5-M8) in Puller 897501-03938}
10 897708-19834 Worm remover Removing worm of auto-oiler
11 897708-37532 Worm inserter Installing worm of auto-oiler
12 897724-01361 Spring pin tool Removing and installing spring pin (4 mm or 5/32 in dia.)
13 897726-09130 Oil seal tool Installing ball bearing on crankshaft
14 897800-79931 Spark tester Checking ignition system
15 897803-30130 Pressure tester Testing carburettor and crankcase leakages
16 897826-16131 Pressure plug Plugging intake / exhaust port to test crankcase / cylinder leakages
17 897827-16131 Pressure plate Plugging intake port to test crank case / cylinder leakages
15 16 17
2 SERVICE HINT
2-1 Assembling clutch
1. Hook both ends of clutch spring together
and install it into the groove of a clutch shoe.
(Note: The hooks should be located at the
centre of shoe groove.)
2. Install clutch hub and the second shoe.
3. Turn over the assembling clutch and install
2 flat springs.
4. Place the third shoe on top of clutch hub
and clutch spring as shown.
(Note: Shoe groove should be located along
clutch spring.)
5. Using thumbs, push down forward the third
shoe as stretching clutch spring on flat and
solid surface until the shoe is engaged
correctly with clutch hub.
6. Install the last flat spring.
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SERVICE HINTCS-3500
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