Echo HCA-2500 User Manual

HCA-250015-23C-00

lNTRODUCTION

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

page

1 SERVICE INFORMATION .............................2

1-1 Specification...............................................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 EMISSION ADJUSTMENT GUIDE ...............7

2-1 General adjusting rules .............................. 7

2-2 Presetting idle adjust screw, L mixture needle

and H mixture needle........................................7

2-3 Adjusting carburettor..................................9

Reference No. 15-23C-00

ISSUED: 200606

INDEX

1 SERVICE INFORMATION

1-1 Specifications

Dimensions Length mm(in) 2330 (91.7)

Width mm(in) 225 (9.3) Height mm(in) 225 (9.3) Dry weight kg(lb) 6.4 (14.1)

Engine Type

Rotation Anticlockwise as viewed from the output end Displacement cm3(in3) 23.6 (1.440) Bore mm(in) 34.0 (1.339) Stroke mm(in) 26.0 (1.024) Compression ratio 6.3

Carburettor Type Rotary type : Diaphragm, horizontal-draught, with primer (purge pump)

Model Walbro WT-424C Venturi size-Throttle bore mm(in) 7.9 - 12.7 (0.31 - 0.5)

Ignition Type CDI (Capacitor discharge ignition) system

Spark plug BPMR7A

Starter Type Automatic rewind

Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)

Fuel Type Premixed two-stroke fuel

Mixture ratio 50 : 1 (2 %) Petrol Minimum 89 octane petrol (RON) Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC

Tank capacity L (U.S.fl.oz.) 0.4 (13.5) Clutch Type Centrifugal, 2 - shoe slide Handle Type Front Rubber grip

Drive shaft Type Flexible

Inner shaft: Diameter - Length mm(in) 6.15 - 1522 (0.24 - 60.0)

Housing OD -ID mm(in) 25 - 22 (0.98 - 0.87) (Main pipe) Length mm(in) 1500 (59.0)

Gear case Reduction ratio 3.95

Gear tooth Spiral bevel

Lubrication Lithium based grease Cutter Type Double reciprocating, double edge blade

Called Length mm(in) 450 (18)

Pitch mm(in) 35.0 (1.38)

Height mm(in) 21.0 (0.83)

Thickness mm(in) 2.5 (0.098)

Articulate adjustment 180° variable at 15° pitch + storage position OD: Outer diameter. ID: Inner diameter.

SERVICE INFORMATION HCA-2500

KIORITZ, air-cooled, two-stroke, single cylinder

with electronic speed governor

Rear Rubber grip with throttle trigger

SERVICE INFORMATIONHCA-2500

1-2 Technical data

Engine

Idling speed r/min 2400 - 3200 Operating speed r/min 7000 - 8000 Wide open throttle speed r/min 9000 - 10500 Clutch engagement speed r/min 3700 - 4300 Compression pressure MPa (kgf/cm2) (psi) 0.94 (9.6) (136)

Ignition system

Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028) Minimum secondary voltage at 1500 r/min kV 15 Primay coil resistance Ω 200 - 400

Secondary coil resistance kΩ 1.3 - 1.8

Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016) Ignition timing at 3000 r/min °BTDC 29

at 8000 r/min °BTDC 28 at 9000 r/min °BTDC 12

Carburettor

Idle adjust screw initial setting turn in* 1 1/2 L mixture needle initial setting turn back 2 1/4 H mixture needle initial setting turn back 3 1/4 Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0) Metering lever height mm(in) 1.65 (0.065) lower than diaphragm seat

BTDC: Before top dead centre. * Set idle speed screw to contact throttle plate before initial setting.

1-3 Torque limits

Descriptions Size kgf•cm N•m in•lbf Starter Pawl carrier M 8 80 - 100 8 - 10 70 - 85

system Ignition Ignition coil (CDI module) M 4* 38 - 55 3.8 - 5.5 35 - 50

system

Fuel Carburettor insulator M 5* 30 - 40 3 - 4 26 - 35 system

Clutch Clutch hub M 8 180 - 200 18 - 20 155 - 175 Engine Crankcase M 5 75 - 85 7.5 - 8.5 65 - 75

Regular bolt, nut and screw M 3 6 - 10 0.6 - 1.0 5 - 9

* Apply thread locking sealant. (See below)

Starter case M 4* 22 - 28 2.2 - 2.8 19 - 24

Spark plug M 14 150 - 170 15 - 17 130 - 150 Fan cover M 4* 38 - 55 3.8 - 5.5 35 - 50

Carburettor M 5 35 - 45 3.5 - 4.5 30 - 40 Throttle wire housing nut M 6 6 - 10 0.6 - 1.0 5 - 9 Fuel tank M 5* 27 - 32 2.7 - 3.2 23 - 28

Cylinder M 5 75 - 85 7.5 - 8.5 65 - 75 Cylinder cover M 4* 35 - 45 3.5 - 4.5 30 - 40 Muffler M 5 55 - 65 5.5 - 6.5 50 - 55 Top guard M 5* 25 - 35 2.5 - 3.5 22 - 30

M4 15 - 25 1.5 - 2.5 13 - 22

SERVICE INFORMATION HCA-2500

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

1-4 Special repairing materials

Material Location Remarks

Grease Drive shaft

Gear case Rewind spring Starter center post

Thread locking sealant Starter case

Ignition coil Fan cover Carburettor insulators Loctite #222, ThreeBond 1342 or equivalent Fuel tank Cylinder cover Top guard Latch PTO shaft

Lithium based grease

Loctite #675 or equivalent

SERVICE INFORMATIONHCA-2500

1-5 Service limits

ABCD

5K193 5K228 5K229 5K230

EFGH

5K231 5K016

5K042 5K194

10 11

5K171

5K232

Description mm (in) A Cylinder bore When plating is worn and aluminium can be seen B Piston outer diameter Min. 33.91 (1.335) 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. 0.05 (0.002) L Clutch drum bore Max. 51.5 (2.03)

120

140

160

180

100

1-6 Special tools

SERVICE INFORMATION HCA-2500

14 : a=3mm

5 : a=4mm

11 12 14

#.014 = .35mm

Ignition Air Gap Gauge

P/N 91004

100

120

140

91019

Key Part Number Description Used for:

1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor 2 363018-00310 Washer Installing crankcase oil seal of starter side 3 433019-12330 Flange nut Removing magneto rotor (flywheel) 4 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4) 5 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5) 6 897701-06030 Bearing wedge Removing ball bearings on crankshaft 7 897701-14732 Bearing tool Removing and installing crankcase bearings 8 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter) 9 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing

10 897712-04630 2-pin wrench Removing and installing pawl carrier

11 897714-22830 Oil seal tool Installing ball bearing in gear case 12 897714-24330 Oil seal tool Installing crankcase oil seals 13 897726-09130 Oil seal tool Removing clutch drum and installing clutch drum ballbearing

14 91004 Module air gap gauge Adjusting pole shoe air gaps 15 897800-79931 Spark tester Checking ignition system

16 897803-30132 Pressure tester Checking carburettor and crankcase leakages 17 897835-16131 Pressure connector Checking crankcase and cylinder leakages 18 900100-08008 Bolt Removing magneto rotor (flywheel) 19 91007 Compression gauge Measuring cylinder compression 20 91019 Limiter cap tool Removing and installing limiter cap

SERVICE INFORMATIONHCA-2500

2 EMISSION ADJUSTMENT GUIDE 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 filter element must be clean and properly installed.

3. The muffler exhaust port must be clear of carbon.

4. The fuel lines, tank vent and fuel filter are in good condition and clear of debris.

5. The fuel is fresh ( > 89 octane : RON) and properly mixed at 50 : 1 with “ISO L-EGD” or “JASO FC” 2stroke oil.

6. The gear case assembly with blade set adjusted clearance properly must be installed for proper engine loading.

B. Set L and H mixture needles with limiter caps minutes alternating engine speed between WOT and idle every 5 seconds. Adjust idle adjust screw to 2800 +/- 300 r/min. Adjust H mixture needle with limiter cap to 10000 +/- 500 r/min. If engine does not run correctly after this adjustment, proceed to the next step

C. After adjusting carburettor according to the steps 2-2 and 2-3, the limiter cap(s) must be installed on L and/or H mixture needle(s) to comply with Emission Directive.

2-2 Presetting idle adjust screw, L mixture needle and H mixture needle

(B)

(A)

91019

anticlockwise to rich side stop. Start and run engine for 2

(2-2).

1. Remove cleaner lid. Turn the L and H mixture needles anticlockwise to rich side stop and meet limiter caps tabs (A) with locating slot (B), using 3 mm blade screw driver.

NOTE : If cap tabs (A) misalign with locating slots

(A)

(B)

(B), there is a chance to strip thread.

2. Screw left hand thread of limiter cap tool 91019 into centre hoIe of limiter cap anticlockwise until tab of the limiter cap just come out from locating slot.

NOTE : DO NOT COMPLETELY REMOVE LIMITER CAP FROM CARBURETOR! If the limiter cap were pulled out completely, there is a chance that the other mixture needle would turn and limiter cap tab would misalign with locating slot when screwing the limiter cap tool into centre hole of the other limiter cap, and thread is stripped. When the thread is stripped by limiter cap tool, screw 3 mm wood screw in the stripped centre hole of the limiter cap, and pull off the cap.

(Continued)

2-2 Presetting idle adjust screw, L mixture needle and H mixture needle (continued)

91019

SERVICE INFORMATION HCA-2500

3. Remove the limiter cap tool from the limiter cap turning the tool clockwise, leaving the limiter cap in place.

4. Screw threaded end of limiter cap tool 91019 into centre hole of the other limiter cap anticlockwise until the limiter cap is come out from the mixture needle completely . Remove the limiter cap from limiter cap tool turning clockwise. Screw thread of limiter cap tool 91019 into centre hole of previous limiter cap to pull out completely.

5. Turn idle adjust screw anticlockwise and set the screw until the tip to just contact throttle plate. Then turn idle adjust screw 1 1/2 turns clockwise. Install removed cleaner lid.

6. Turn L and H mixture needle clockwise until lightly seated, and then turn both mixture needles anticlockwise following turns.

L mixture needle : 2 1/4,

NOTE : If needles are forced during seating, damage to carburettor may occur.

H mixture needle : 3 1/4

2-3 Adjusting carburettor

SERVICE INFORMATIONHCA-2500

idle adjust screw

1. Start engine and warm it up speed between WOT and idle every 5 seconds for 1 minute

2. Using 2.5 mm wide blade screw driver, adjust L mixture needle to obtain maximum idle speed.

3. Set idle speed in the range of 3,400 to 3,500 r/min by turning idle adjust screw.

4. Turn L mixture needle anticlockwise to reduce engine idle speed 700 to 800 r/min to set idle speed in the range of 2,600 to 2,800 r/min.

NOTE : Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings.

5. Turn H mixture needle anticlockwise to reduce engine speed to approx. 9,000 r/min at WOT.

6. Turn H mixture needle clockwise to obtain 9,500 to 10,500 r/min at WOT.

NOTE : During H mixture needle adjustment, do not run engine at high speed without load longer than 10 seconds.

alternating engine

7. If the engine speed at WOT is above 10,500 r/min, adjust H mixture needle anticlockwise and set maximum engine speed at less than 10,500 r/min.

(Continued)

2-3 Adjusting carburettor (Continued)

(B)

(A)

SERVICE INFORMATION HCA-2500

8. After adjusting carburettor, put new limiter cap on the other side of limiter cap tool as shown, and press the limiter caps to the bottoms on L and H mixture needles respectively.

NOTE : Align the limiter cap’s tabs (A) with locating slots (B) in extended housing of carburettor.

IMPORT ANT : The limiter caps must be installed L and H mixture needles to comply with

(A)

(B)

Emission Directive.

9. Start engine again and make sure engine runs at idle speed in the range of 2,400 to 3,200 r/min and at WOT engine speed in the range of 9,000 to 10,500 r/min. Also make sure blade would not move at engine idle speed and suitable acceleration.

NOTE : Initial carburettor setting (Idle adjust screw, L and H mixture needles) shown on page 3 and 8 is to start the engine after restoration or carburettor change. Idle adjust screw, L and H 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, variance would be ignorable.

Echo HCA-2500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual