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21-25G-00
PB-265ESL
1
2
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.
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 Presetting idle adjust screw, idle mixture
needle and hi speed (H) mixture needle
2-3 Adjusting carburettor................................... 8
Reference No.
.............................. 2
21-25G-00
page
.. 7
............... 7
ISSUED: 200712
INDEX
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1 SERVICE INFORMATION
1-1 Specifi cations
Dimensions Length* mm(in) 305 (12.0)
Width* mm(in) 410 (16.1)
Height mm(in) 435 (17.1)
Dry weight** kg(lb) 6.1 (13.4)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Anticlockwise as viewed from the output end
Displacement cm
Bore mm(in) 34.0 (1.34)
Stroke mm(in) 28.0 (1.10)
Compression ratio 7.0
Carburettor Type Rotary type : Diaphragm, horizontal-draught, with primer
Model ZAMA RB-K85
Ignition Type CDI (Capacitor discharge ignition) system
Spark plug BPMR8Y
Exhaust Muffl er type Spark arrestor muffl er with catalyst
Starter Type ES (effortless-start)
Rope diameter x length mm(in) 3.0 x 815 (1/8 x 32.1)
Fuel Type
Mixture ratio 50 : 1 (2%)
Petrol Minimum 89 octane
Two-stroke engine oil
Tank capacity L (U.S.fl .oz.) 0.66 (22.3)
Blower Fan type Centrifugal, single stage
End type Curved pipe
Max. air volume (with pipes)
m
Max. air velocity (with pipes)
m/s (mph)
Discharge ID†† mm(in) 62 (2.44)
SERVICE INFORMATION PB-265ESL
3
(in3) 25.4 (1.55)
Variable Slope Timing (VST) : Slope advance ignition
system combined with electronic speed governor
†
Premixed two-stroke fuel
3
/min ( ft3/min)
ISO-L-EGD (ISO/CD13738), JASO FC/FD
9.3 (361)
59.0 (132)
*Without blower pipes **With all blower pipes †Refer to Operator’s manual. ††ID : Inner diameter
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SERVICE INFORMATIONPB-265ESL
1-2 Technical data
Engine
Idling speed r/min 2800 - 3200
Wide open throttle speed r/min 6700 - 7200
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 160 - 400
Secondary coil resistance kΩ 2.5 - 3.2
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing at 1000 r/min °BTDC 7
at 3000 r/min °BTDC 18
at 7000 r/min °BTDC 31
Carburettor
Idle mixture needle initial setting turns back 4 3/4
H mixture needle initial setting turns back 1 1/8
Idle adjust screw initial setting turns back* 5
Test Pressure, minimum MPa (kgf/cm
Metering lever height mm (in) 0.1 - 0.25 (0.004 - 0.010) lower than diaphragm seat
2
) (psi) 0.83 (8.4) (120)
2
) (psi) 0.05 (0.5) (7.0)
3
BTDC: Before top dead centre.
*Refer to page 7 on 2-2 initial idle adjust screw.
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SERVICE INFORMATION PB-265ESL
1-3 Torque limits
Descriptions
Size
kgf•cm
2N•m
in•lbf
Starter Starter pawl M 8* 130 - 150 13 - 15 115 - 130
system
Starter case M 5
†
20 - 40 2 - 4 17 - 35
Ignition Ignition coil M 4 35 - 45 3.5 - 4.5 30 - 40
system
Spark plug M 14 150 - 170 15 - 17 130 - 150
Fuel Carburettor insulator M 5 50 - 70 5 - 7 45 - 60
system
Carburettor M 5 35 - 45 3.5 - 4.5 30 - 40
Engine Crankcase M 5 70 - 110 7 - 11 60 - 95
Cylinder M 5 70 - 110 7 - 11 60 - 95
Cylinder cover M 5 60 - 80 6 - 8 50 - 70
Cylinder cover with lead M 5 40 - 60 4 - 6 35 - 50
Engine mount M 4* 30 - 45 3 - 4.5 25 - 40
Muffl er M 5 70 - 80 7 - 8 60 - 70
Muffl er cover M 5* 30 - 45 3 - 4.5 25 - 40
Others Outer fancase M 5
†
20 - 40 2 - 4 17 - 35
Fan M 8 140 - 160 14 - 16 120 - 140
Fan hub M 8 160 - 200 16 - 20 140 - 175
Backpack fl ame
compression spring
Fan case assembly
to backpack fl ame
Upper
Lower
M 5
M 5
M 5
†
†
†
20 - 40 2 - 4 17 - 35
25 - 50 2.5 - 5 20 - 45
30 - 50 3 - 5 25 - 45
Throttle lever assembly M 5 35 - 50 3.5 - 5 30 - 45
Trigger arm M 5 12 - 18 1.2 - 1.8 10 - 16
Trigger fi xture M 5 10 - 20 1 - 2 8 - 18
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
* Apply thread locking sealant (See below)
** The torque differences among four bolts should not exceed 20 kgf•cm (2N•m, 17in•lbf) on one cylinder or crank-
case.
†
Tapping screw or tapping bolt
1-4 Special repairing materials
Material
Thread locking sealant Engine mount
Fun hub
Starter pawl
Muffl er cover
Grease Rewind spring
Starter centre shaft
Location
Remarks
Loctite # 242, ThreeBond 1324 or equivalent
Loctite # 222, ThreeBond 1342 or equivalent
Lithium based grease or ECHO LUBE
TM
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SERVICE INFORMATIONPB-265ESL
5K016
5K263 5K264 5K265
5K266
5K204
5K017
5K219
5K171
5K267
1-5 Service limits
ABCD
EFGH
5
KL
Description mm (in)
A Cylinder bore When plating is worn and aluminum 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. 1.3 (0.051)
E Piston ring side clearance Max. 0.1 (0.004)
F Piston pin outer diameter Min. 7.980 (0.3142)
G Piston ring width Min. 1.15 (0.045)
H Piston ring end gap Max. 0.5 (0.02)
K Con-rod small end bore Max. 11.988 (0.4719)
L Crankshaft runout Max. 0.05 (0.002)
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1-6 Special tools
1
SERVICE INFORMATION PB-265ESL
2
3
4
5
9
13
14
6
10
15
7
11
50
0.4
0
0.8
0
1.2
MPa
1.
16
ECHO
8
12
Ignition
Air Gap Gauge
#.014 = .35mm
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 91004 Module air gap gauge Adjusting pole shoe air gaps
9 897712-04630 2-pin wrench Removing and installing pawl carrier
10 897726-16431 Oil seal tool Installing crankcase oil seals
11 990511-30023 Spark tester Checking ignition system
12 897803-30133 Pressure tester Checking carburettor and crankcase leakages
13 900100-08008 Bolt Removing magneto rotor (fl ywheel)
14 433019-12330 Flange nut Removing magneto rotor (fl ywheel)
15 91037 Compression gauge Measuring cylinder compression
16 91020 Limiter plug tool Removing and installing plug
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SERVICE INFORMATIONPB-265ESL
2 CARBURETTOR ADJUSTMENT PROCEDUTER
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.
5. The fuel is fresh ( > 89 octane : RON ) and properly mixed at 50 : 1 with “ISO L-EGD” or “JASO FC/
FD” 2 stroke oil.
6. All blower pipes are installed for proper engine loading.
B. Start and run engine for 3 minutes alternating rpm between WOT for 50 seconds and idle for 10
seconds. Adjust idle speed screw to 3,000 +/- 200 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 on Idle and hi speed mixture needle to comply with Emission Directive.
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2-2 Presetting idle adjust screw, idle mixture needle and hi speed (H) mixture needle
Tools Required : Small screwdriver with 2.5 mm
blade, P/N 897801-33330 electronic tachometer,
P/N 91020 limiter plug removal tool. Parts Required : (2) P/N A259-000010 limiter plugs.
1. Remove plugs from Idle mixture needle hole (A)
and H 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)Screw limiter plug tool anticlockwise 2 turns into
limiter plug pushing the tool again the plug to engage the tool threads.
(3)Pull out limiter plug tool with the limiter plug
from mixture needle hole.
(4)Repeat plug removal procedure for the other
mixture needle.
NOTE : If the plug is damaged and left in the hole,
use a needle or pin-shaped tool to remove deformed plug pieces.
2. Turn hi mixture needle (B) clockwise until lightly
seated. And then turn hi speed mixture needle
counterclockwise 1 1/8 turns. Turn idle mixture
needle (A) clockwise until lightly seated. And then
turn L mixture needle anticlockwise 4 3/4 turns.
(C)
(D)
(1)
(2)
(3)
(A)
(B)
(A)
(G)
(D)
3. Turn idle adjust screw (D) clockwise until its
Fig 1
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, variance would be ignorable.
Initial carburettor setting (Idle adjust screw, idle and hi speed mixture needles) shown here is to
head touches boss (G) as shown Fig1. Then turn
idle adjust screw (D) anticlockwise 5 turns.
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2-3 Adjusting carburettor
SERVICE INFORMATION PB-265ESL
(E)
(D)
(A)
1. Start engine and warm it up alternating engine
speed between WOT and idle every 10 seconds
for 1 minute.
2. Adjust idle mixture needle (A) with 2.5 mm blade
screwdriver (E) to reach maximum engine speed
just before drop off.
3. Set idle speed to 3,500 r/min by turning idle adjust screw (D). Engine rpm should be stable at 3,500
+/- 10 r/min.
4. Turn idle mixture needle (A) anticlockwise to
reduce idle speed 500 to 600 r/min in the range of
2,900 to 3,000 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 (B) and obtain
maximum WOT engine speed just before lean drop
off using 2.5 mm blade screwdriver.
Engine speed must be allowed to stabilize
(B)
6. Turn hi speed mixture needle (B) anticlockwise
to reduce WOT engine speed 10-20 r/min. Minimum WOT engine speed after adjusting should be
over 6,700 r/min.
7. Start engine, and verify engine idle speed ranges from 2,800 to 3,200 r/min, and WOT engine
speed ranges from 6,700 to 7,200 r/min. When
final adjustment is completed, the engine should
idle, accelerate smoothly, and attain WOT per
above specifi cation.
8. After adjusting carburettor, insert and secure
new plug(s) (F) A259-000010 deep in the needle
holes per the Emission Directive using limiter plug
tool.
NOTE :
operation may vary from fi nal adjustment specifi ca-
tions 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 carburettor should be
readjusted.
Engine WOT, and idle speed in field
(C)
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