HCR-151012-21L-01
1
1
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 and directions in this SERVICE
DATA are based on the latest products
information available at the time of
publication.
INDEX
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 ......................... 5
1-5 Service limits .............................................. 6
1-6 Spacial tool ................................................. 7
2 EMISSION ADJUSTMENT GUIDE ............... 8
2-1 General adjusting rules .............................. 8
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle ........................................ 8
2-3 Adjusting carburettor .................................. 9
Reference No. 12-21L-01
REVI SED: 201001
ISSUED: 200512
2
1 SERVICE INFORMATION
1-1 Specifications
Model HCR-1510
Dimensions Length mm(in) 990 (39.0)
Width mm(in) 250 (9.8)
Height mm(in) 195 (7.7)
Dry weight kg(lb) 5.2 (11.5)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Anticlockwise as viewed from the output end
Displacement cm3(in3) 21.2 (1.29)
Bore mm(in) 32.2 (1.27)
Stroke mm(in) 26.0 (1.02)
Compression ratio 6.1
Carburettor Type Diaphragm, horizontal-draught, with primer (purge bulb)
Model ZAMA C1U-K54A
Ignition Type CDI (Capacitor discharge ignition) system
Spark plug BPMR-7A
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
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.) 0.3 (10.1)
Clutch Type Centrifugal, 2-shoe slide
Handle Type Front Plastic grip with hand guard
Gear case Reduction ratio 4.5
Gear tooth Spur gear
Lubrication Lithium based grease
Cutter Type Double reciprocating double edge blade
Called length mm(in) 580 (23)
Pitch mm(in) 35 (1.38)
Height mm(in) 21 (0.83)
Thickness mm(in) 2.5 (0.098)
Lubrication Drop a few oil every 4 hours of operation to 4 bolt slots
SERVICE INFORMATION
Variable Slope Timing (VST) : Slope advance ignition
system combined with electronic speed governor
Rear Integrated control plastic grip
(Grease up every 15-20 hours of operating)
HCR-1510
HCR-1510
1-2 Technical data
Engine
Idling speed r/min 2400 - 3200
Wide open throttle speed r/min 7900 - 8500
Clutch engagement speed r/min 3500 - 4100
Compression pressure MPa (kgf/cm2) (psi) 0.69 (7.0) (100)
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 250 - 400
Secondary coil resistance kΩ 2.4 - 3.2
Pole shoe air gaps mm(in) 0.30 - 0.35 (0.012 - 0.014)
Ignition timing at 3000 r/min °BTDC 20.0
at 7000 r/min °BTDC 42.0
at 8000 r/min °BTDC 19.0
at 8500 r/min °BTDC 15.0
Carburettor
Venturi size mm(in) 8.5 (0.34)
Throttle bore mm(in) 12.7 (0.5)
Idle adjust screw initial setting turn in* 2 3/4
H mixture needle initial setting turn back 1 1/2
L mixture needle initial setting turn back 1 1/2
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
BTDC: Before top dead centre.
* Set idle speed screw to contact throttle plate before initial setting.
SERVICE INFORMATION
3
4
1-3 Torque limits
Descriptions Size kgf•cm N•M in•lbf
Starter Pawl assembly M 8 160 - 200 16 - 20 140 - 175
system
Ignition Ignition coil M 4 35 - 50 3.5 - 5.0 30 - 45
system
Fuel Carburettor M 5 25 - 40 2.5 - 4.0 22 - 35
system
Clutch Clutch hub M 8 160 - 200 16 - 20 140 - 175
Engine Crankcase M 5** 70 - 110 7 - 11 60 - 95
Gear Gear case M 5 50 - 70 5 - 7 45 - 60
case Bottom cover M 4 30 - 50 3 - 5 26 - 45
Cutter Cutter bolts (See NOTE below) M 6 10 - 15 1.0 - 1.5 9 - 13
Handle Rear handle set to
Starter case M 4* 14 - 28 1.4 - 2.8 12 - 24
Spark plug M 14 150 - 170 15 - 17 130 - 150
Intake insulator M 5* 25 - 40 2.5 - 4.0 22 - 35
Fuel tank M 5* 30 - 45 3.0 - 4.5 26 - 40
Clutch case M 4* 30 - 50 3 - 5 26 - 45
Cylinder M 5** 70 - 110 7 - 11 60 - 95
Muffler M 5 60 - 100 6 - 10 50 - 90
Cylinder cover M 4* 14 - 28 1.4 - 2.8 12 - 24
Cutter support M 6* 45 - 75 4.5 - 7.5 40 - 65
handle fixture
SERVICE INFORMATION
M 5* 25 - 40 2.5 - 4.0 22 - 35
HCR-1510
Front handle M 5 30 - 45 3.0 - 4.5 26 - 40
Regular bolt, nut and screw
* Apply thread locking sealant (See next page).
** The torque differences among 2 bolts should not exceed 20 kgf•cm (2Nm, 17in•lbf) on one cylinder or
crankcase.
NOTE : To adjust cutter clearance, fasten all cutter bolts to this torque, then back 1/2 turns (180°) Anticlockwise.
M4 15 -25 1.5 - 2.5 13 - 22
M3 6 -10 0.6 - 1.0 5 - 9
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
HCR-1510
1-4 Special repairing materials
Material Location Remarks
Grease Gear case
Rewind spring
Starter center post
Oil seal inner lips
Thread locking Intake insulator
sealant
Clutch case
Cylinder cover
Fuel tank Loctite #222, ThreeBond 1342 or equivalent
Cutter support
Starter case
Rear handle set to handle fixture
SERVICE INFORMATION
Lithium based grease
5
6
0
5
10
1
23
4
5
6
7
8
9
10
11
SERVICE INFORMATION
HCR-1510
1-5 Service limits
ABCD
EFGH
5K016 5K042
KL
5K171
5K202
Servicelimits_HCR_1510
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. 0.05 (0.002)
L Clutch drum bore Max. 51.5 (2.03)
HCR-1510
20
40
60
80
120
140
160
180
20
100
1-6 Special tools
SERVICE INFORMATION
7
13 : a=4mm
6
25
789
80
100
60
120
40
140
20
160
180
20
4 : a=3mm
10 11 12
14
15
16
a
13
Key Part Number Description Used for:
1 897801-33330 Tachometer (PET-1000) Measuring engine speed to adjust carburettor
2 91007 Compression gauge Measuring cylinder compression
3 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolts (M5)
4 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4)
5 897701-06030 Bearing wedge Removing ball bearings on crankshaft
6 897701-14732 Bearing tool Removing and installing crankcase bearings
7 897702-30131 Piston pin tool Removing and installing piston pin (Use 8 mm dia. adapter)
8 897712-07930 2-pin wrench Removing and installing pawl carrier
9 897714-24330 Oil seal tool Installing crankcase oil seals
10 897718-02830 Bearing tool Installing clutch drum ball bearing in gear case
11 897731-04920 Clutch tool Removing and installing clutch assembly
12 897800-79931 Spark tester Checking ignition system
13 897803-30131 Pressure tester Checking carburettor and crankcase leakages
14 897835-16131 Pressure connector Checking crankcase and cylinder leakages
15 900100-08008 Bolt Removing magneto rotor (flywheel)
16 433019-12330 Flange nut Removing magneto rotor (flywheel)
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2 EMISSION ADJUSTMENT GUIDE
2-1 General adjusting rules
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” 2 stroke oil.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
SERVICE INFORMATION
1. Turn L mixture needle (A) clockwise until lean
stop to cut and remove easily.
2. Using a sharp knife, give triangle cut between
the stopper wings. Also cut the H limiter cap (B).
HCR-1510
NOTE : Be careful when cutting caps, otherwise
injury may result.
3. Pull the caps off with pliers.
NOTE : Do not rock back and forth when removing,
otherwise the needle may be damaged.
4. Turn H and L mixture needles clockwise until
lightly seated.
NOTE : Do not over tighten needles, otherwise
needles tip and seat damage may occur.
5. Turn L mixture needle anticlockwise 1 1/2 turns.
B
A
C
Turn H mixture needle anticlockwise 1 1/2 turns.
6. Turn idle adjust screw (C) anticlockwise and set
the screw until the tip to just contact throttle plate.
Then turn it clockwise 2 3/4 turns.
HCR-1510
2-3 Adjusting carburettor
D
SERVICE INFORMATION
1. Start engine and warm it up well for about 3 - 5
minutes with cycle of 5 seconds at WOT (Wide Open
Throttle) and 10 seconds at idling.
2. Adjust L mixture needle and obtain maximum idle
speed with 2.5 mm wide blade head screw driver
(D).
3. Set idle speed to 3,800 r/min by turning idle adjust
screw.
4. Turn L mixture needle anticlockwise to reduce
idle speed 1,000 r/min to set idle speed in the range
of 2,600 to 3,000 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 clockwise to maximum
WOT engine speed then turn the H mixture needle
clockwise further until engine speed drops 100 to
200 r/min.
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6. Immediately return the H mixture needle
anticlockwise to obtain maximum WOT engine
speed with smooth and clear engine sound. Then
turn the H mixture needle anticlockwise 1/8-1/4 turn
further.
7. After adjusting carburettor, install Red limiter cap
on H mixture needle and White limiter cap on L
mixture needle to the rich side stop as shown.
NOTE : Before installing limiter caps, warm caps in
90 °C hot water for smooth installation. Make it sure
to use pliers or appropriate instrument to take
warmed up cap out from the water.
(Continued)
10
2-3 Adjusting carburettor (Continued)
SERVICE INFORMATION
8. Press respective limiter caps to the bottoms using
bar tool like T hex. wrench (E).
IMPORTANT : The limiter caps must be installed
on L and H mixture needles to comply with Emission
Directive.
9. Start engine again and make it sure engine runs
in the range of 2,400 to 3,200 r/min at idling and the
range of 7,900 to 8,500 r/min at WOT. Also make it
sure cutting device would not turn at engine idle
speed and suitable acceleration.
HCR-1510
E
NOTE : Initial carburettor setting (Idle adjust screw,
L and H mixture needles) shown here is to start the
engine after restoration or carburettor change. Idle
adjust screw, L and H 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.
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