Page 1
10-21P-02
GT-220ES, SRM-220ES
SERVICE DATA
TRIMMER/BRUSHCUTTER
GT-220ES
1
1
SRM-220ES
(Serial nember : 36000001 and after)
STAGE MODEL
(Serial nember : 37000001 and after)
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.
CONTENTS
1 SERVICE INFORMATION
1-1 Specifi cation ............................................... 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 CARBURETTOR ADJUSTMENT PROCEDURE
2-1 General adjusting rules ............................... 7
2-2 Initial Idle adjust screw, Idle mixture
and Hi speed mixture needle settings ................... 7
2-3 Adjusting carburettor................................... 8
.............................. 2
page
...
needle
7
INDEX
Reference No.
REVISED: 200901
10-21P-02
ISSUED: 200705
Page 2
GT-220ES
2
1 SERVICE INFORMATION
1-1 Specifi cations
Model
GT-220ES
Dimensions Length* mm(in) 1460 (57.4) 1760 (69.3)
Width mm(in) 320 (12.6) 345 (13.5) 655 (25.7)
Height mm(in) 575 (22.6) 320 (12.6) 420 (16.5)
Dry weight * kg(lb) 4.4 (9.7) 5.0 (11.1) 5.1 (11.2)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Anticlockwise as viewed from the output end
Displacement cm
Bore mm(in) 32.2 (1.268)
Stroke mm(in) 26.0 (1.024)
Compression ratio 5.9
Carburettor Type
Model ZAMA RB-K93
Venturi size-Throttle bore mm(in) 9.0 - 10.5 (0.35 - 0.41)
Ignition Type CDI (Capacitor discharge ignition) system
Variable Slope Timing (VST) : Slope advance ignition
Spark plug BPMR8Y
Exhaust Muffl er type 36 series : Spark arrestor muffl er
37 series : Spark arrestor muffl er with catalyst
Starter Type ES (effortless-start)
Rope diameter x length mm(in) 3.0 x 820 (0.12 x 32.2)
Fuel Type Premixed two-stroke fuel
Mixture ratio
Petrol Minimum 89 octane petrol (RON)
Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC/FD
Tank capacity L (U.S.fl .oz.) 0.4 (13.5)
Clutch Type Centrifugal, 2 - shoe slide
Handle Type Front D-loop
Rear
Drive shaft Type Flexible
Diameter - Length mm(in)
Housing OD -ID mm(in) 25 - 22 (0.98 - 0.87)
(Main pipe) Length mm(in)
Gear case Reduction ratio --- 1.36
Gear tooth --- Spiral bevel gear
Lubrication Lithium based grease
Cutter Type Nylon line head Metal blade
Fastener type, size mm Standard thread Left-hand thread nut, M10 x 1.25 pitch
Cutting rotation
SERVICE INFORMATION
3
(in3) 21.2 (1.294)
Rotary valve type: Diaphragm, horizontal-draught, with primer
system combined with electronic speed governor
50 : 1 (2 %)
Integrated control grip with cushion
6.0 - 1330 (0.24 - 52.4)
1330 (52.4)
3/8 inch - 24UNF
Clockwise as viewed
from top
SRM-220ES (L) SRM-220ES (U)
6.0 - 1520 (0.24 - 59.8)
1500 (59.1)
Anticlockwise as viewed from top
SRM-220ES
U-handle with
integrated control grip
OD: Outer diameter. ID: Inner diameter.
* Without shoulder harness and cutter head.
Page 3
GT-220ES
SRM-220ES
1-2 Technical data
Model
GT-220ES SRM-220ES (L) SRM-220ES (U)
Engine
Idling speed r/min 2600 - 3400
Wide open throttle speed r/min 7000 - 8000* 8000 - 9700* 9500 - 11500**
Clutch engagement speed r/min 3500 - 4100
Compression pressure MPa (kgf/cm
Ignition system
Spark plug gap mm (in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1500 r/min kV 15
Primary coil resistance Ω 130 - 200
Secondary coil resistance kΩ 1.0 - 2.0
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing at 3000 r/min °BTDC 27
at 8000 r/min °BTDC 42
Carburettor
Venturi Size mm(in) 9.0 (0.354)
Throttle Bore mm(in) 10.5 (0.413)
Idle adjust screw initial setting turn in*** 1 1/2 2 1/2
Idle mixture needle initial setting turn back†
Hi speed mixture needle initial setting turns back
Test pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 0.1-0.25 (0.004-0.010) lower than diaphragm seat
SERVICE INFORMATION
2
) (psi) 0.74 (7.6) (108)
†
1 3/8
2 3/4
3
BTDC: Before top dead centre.
* With two line nylon line head.
** With metal blade.
*** Set idle speed screw to the point that its tip just contacts throttle plate before initial setting.
†
Turn Idle/Hi speed mixture needles anticlockwise from point that needle is lightly seated.
Page 4
GT-220ES
4
1-3 Torque limits
Descriptions Size
Starter Starter case
system
Ignition Ignition coil M 4 30 - 50 3 - 5 26 - 45
system
Ground lead terminal M 4** 20 - 40 2 - 4 18 - 35
Fuel Intake insulator M 5** 25 - 40 2.5 - 4 22 - 35
system
Throttle cable nut M 6 25 - 35 2.5 - 3.5 22 - 30
Fuel tank M 5** 30 - 45 3.0 - 4.5 26 - 40
Clutch Clutch hub M 8 120 - 160 12 - 16 100 - 140
Engine Crankcase M 5
Cylinder M 5† 70 - 100 7 - 10 60 - 90
Cylinder cover M 4 14 - 28 1.4 - 2.8 12 - 24
Muffl er M 5 60 - 100 6 - 10 52 - 85
Top guard M 5* 15 - 25 1.5 - 2.5 13 - 22
Others Trigger holder assembly M 5 35 - 55 3.3 - 5.5 30 - 48
Regular bolt, nut and screw M 3 6 - 10 0.6 - 1 5 - 9
M 4 15 - 25 1.5 - 2.5 13 - 22
M 5 25 - 45 2.5 - 4.5 22 - 40
M 6 45 - 75 4.5 - 7.5 40 - 65
M 8 110 - 150 11 - 15 95 - 130
M 10 210 - 300 21 - 30 180 - 260
Fan cover M 4** 14 - 28 1.4 - 2.8 12 - 24
Spark plug M 14 150 - 170 15 - 17 130 - 150
Carburettor M 5 30 - 40 3 - 4 26 - 35
Trigger holder assembly band
SERVICE INFORMATION
M 4 14 - 28 1.4 - 2.8 12 - 24
†
70 - 100 7 - 10 60 - 90
M 5 20 - 40 2 - 4 18 - 35
kgf•cm
N•m
SRM-220ES
in•lbf
*Tapping screw ** Apply thread locking sealant. (See below)
†
The torque differences among bolts should not exceed 20 kgf•cm (2N•m, 17in•lbf) on one cylinder or
crankcase.
1-4 Special repairing materials
Material
Thread locking sealant Fan cover
Intake insulator
Ground lead terminal
Fuel tank
Grease Gear case
Rewind spring Lithium based grease
Starter center post
Location
ThreeBond 1342 or equivalent
Remarks
Page 5
GT-220ES
5K016 5K042
5K171
5K228A 5K229A 5K230
5K231A
0
1
2
3
4
5
6
7
5K071A
5K268
5K269
SRM-220ES
1-5 Service limits
ABCD
EFGH
SERVICE INFORMATION
5
KL
Description mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 32.10 (1.264)
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. 7.970 (0.3138)
G Piston ring width Min. 1.45 (0.057)
H Piston ring end gap Max. 0.5 (0.02)
K Crankshaft runout Max. 0.03 (0.001)
L Clutch drum bore Max. 51.5 (2.03)
Page 6
6
1-6 Special tools
1
GT-220ES
SERVICE INFORMATION
2
3
4
SRM-220ES
5
9
13
14
6
10
15
16
ECHO
7
11
17
8
12
50
0.4
0.8
0
0
1.2
MPa
1.
18
#.014 = .35mm
Ignition Air Gap Gauge
P/N 91004
Key Part Number Description Used for:
1 897801-33330 Tachometer PET-1000 Measuring engine speed
2 363018-00310 Washer Installing crankcase oil seal of starter side
3 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)
4 897603-23030 PTO shaft puller Removing driven (PTO) shaft
5 897701-06030 Bearing wedge Removing ball bearings on crankshaft
6 897701-14732 Bearing tool Removing and installing crankcase ball bearings
7 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter.)
8 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing
9 897712-04630 2-pin wrench Removing and installing pawl carrier
10 897726-09130 Oil seal tool Installing crankcase oil seals
11 897800-79931 Spark tester Checking ignition system
12 897803-30131 Pressure tester Checking carburettor and crankcase leakages
13 897835-16131 Pressure connector Checking crankcase and cylinder leakages
14 433019-12330 Flange nut Removing magneto rotor (fl ywheel)
15 900100-08008 Bolt Removing magneto rotor (fl ywheel)
16 91020 Limiter plug tool Removing and installing plug
17 91037 Compression gauge Measuring cylinder compression
18 91004 Module air gap gauge Adjusting pole shoe air gaps
Page 7
GT-220ES
SRM-220ES
2 CARBURETTOR ADJUSTMENT PROCEDURE
2-1 General adjusting rules
A. Before starting the unit for adjustment, check the following items.
1. The correct spark plug must be clean and properly gapped.
2. The air fi lter element must be clean and properly installed.
3. The muffl er exhaust port must be clear of carbon.
4. The fuel lines, tank vent and fuel fi lter are in good condition and clear of debris.
SERVICE INFORMATION
7
5. The fuel is fresh ( > 89 octane :
2-stroke oil.
6. Two nylon line head with properly cut lines is recommended to be installed for proper engine loading.
B.
Start and run engine for 3 minutes alternating engine speed between WOT for 10 seconds and idle for
5 seconds. Adjust idle speed screw to 3,000 +/- 100 r/min. If engine does not run correctly after this adjustment, proceed to the next step 2-2.
IMPORTANT : After adjusting carburettor according to the steps 2-2 and 2-3, the limiter plug(s) must
be installed in Idle and Hi speed mixture needle(s) hole(s) to comply with Emission Directive.
2-2 Initial Idle adjust screw, Idle mixture needle and Hi speed mixture needle settings
(A)
(E)
(D)
RON
) and properly mixed at 50 : 1 with “ISO L-EGD” or “JASO FC/FD”
(A)
(B)
Parts Required : (2) limiter plug P/N P005-001270
1. Remove plugs from Idle mixture needle hole (A)
and Hi speed mixture needle hole (B) using limiter
plug tool (C) as follows.
1) Put limiter plug tool (C) on limiter plug in mixture
needle hole.
2) Turn limiter plug tool anticlockwise 2 turns slowly into limiter plug while pushing the tool.
3) Pull out limiter plug tool with the limiter plug from
mixture needle hole.
1) 2)
(C)
3)
(F)
(E)
Turn Idle mixture needle (D) clockwise completely until lightly seated.
2.
turns. Turn Hi speed mixture needle (G) clockwise until lightly seated. Then turn it anticlockwise 1 3/8 turn.
3. Turn Idle adjust screw (E) anticlockwise until screw tip just touches throttle plate (F). Then turn it in
clockwise 1 1/2 (GT-220ES), 2 1/2 (SRM-220ES) turns.
NOTE :
start the engine after restoration or carburettor change. Idle adjust screw, Idle and Hi speed mixture needles turn for designated engine revolution through procedures indicated here may vary. As long as idle
and WOT engine speed is set in given range, the variance would be ignorable.
Initial carburettor setting (Idle adjust screw, Idle and Hi speed mixture needles) shown here is to
(G)
NOTE :
use hand auger or pin-shaped tool to scrape and
lift the plug pieces out of the hole.
If plug is damaged and stays in the hole,
Then turn it anticlockwise 2 3/4
Page 8
8
2-3 Adjusting carburettor
SERVICE INFORMATION
1. Start and warm up engine alternating engine
speed between WOT for 10 seconds and idle for 5
seconds for 3 minute.
GT-220ES
SRM-220ES
NOTE :
needle clockwise in 1/4 turn increments until the
engine starts.
2. Adjust Idle mixture needle to reach maximum
idle speed with 2.5 mm blade screwdriver.
3. Set idle speed to 3,800 r/min by turning Idle adjust screw. Engine speed should be stable at 3,800
+/- 50 r/min.
4. Turn Idle mixture needle anticlockwise to reduce engine idle speed 800 r/min to set idle speed
at 3,000 r/min. The idle speed range is 2,900 - 3,100
r/min.
NOTE :
a minimum of 20 seconds after each adjustment of
idle mixture needle to assure accurate tachometer
readings.
5. Adjust Hi speed mixture needle to reach maximum WOT engine speed.(maximum approximate
7,300 r/min on GT-220ES, 8,800 r/min on SRM220ES with nylon line head, 10,500 r/min on SRM220ES with metal blade.) Then turn Hi speed
mixture needle anticlockwise to reduce WOT engine speed 20 r/min.
If the engine can’t start, turn Idle mixture
Engine speed must be allowed to stabilize
(J)
(H)
(J)
6. Start engine again and verify engine idle speed
ranges from 2,600 to 3,400 r/min, and WOT engine speed ranges from 7,000 r/min to 8000 r/min
on GT-220ES, 8,000 r/min to 9,700 r/min on SRM220ES with nylon line head, 9,500 r/min to 11,500
r/min on SRM-220ES with metal blade. Make sure
the cutter does not rotate when engine is idling.
When final adjustment is completed, the engine
should idle, accelerate smoothly, and attain WOT
per above specifi cations.
7. After adjusting carburettor, completely insert and
secure new plug (s) (J) P005-001270 deep in the
needle holes per the Emission directive using limiter plug tool (H).
NOTE :
field operation may vary from final adjustment
specifi cations due to changing ambient conditions,
fuel, and engine loads. Safe engine speed variances should be within the WOT and Idle speed
ranges listed in Section 1-1, otherwise the carburetor should be readjusted.
Engine WOT, and idle engine speed in
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