Elektrolux 18cc, 21cc, 24cc User Manual

For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983

SERVICE MANUAL FOR WEED EATER/POULAN/POULAN PRO

18cc,21cc AND 24cc ENGINES

LT7000;LT7500;FEATHERLITE SERIES;WT21;PP110;PT112;PP113;PT115;PT165;

LT17; PROLITE; TWIST-N-EDGE(TE) UNITS; ULTRATRIM

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1. SCREW SPECIFICATIONS

TORQUE
PART NO. LOCATION (QTY) SIZE (IN-LBS)

CRANKCASE & CYLINDER

530015953 CYLINDER/CRANKCASE (2) 1/4 – 20 90-100
952030201 SPARK PLUG (1) 14mm 11-15(FT LBS)

530015810 FAN HSG/CRANKCASE (4) 10 - 24 40 - 50
530016014 CARB ADAPTER/CYL (2) 12 - 24 50 - 60
530015887 CARB/CARB ADAPTER(2) 9 - 15 60 - 70
530015966 AIR BOX COVER/BOX (2) 10 - 14 10 - 15

IGNITION SYSTEM

530038604 DRIVE COUPLING (1) 5/16 - 24 10 – 12(FT LBS)
530015954 MODULE/CRANKCASE (2) 8 – 32 30 - 40

STARTING SYSTEM, FAN HOUSING & CLUTCH HOUSING

530015882 STARTER DOG/FLYWHEEL (2) 6 - 19 8 - 12
530016080 PULLEY/ROPE (1) 6 - 19 10 - 12
530015886 CLUTCH HSG/FAN HSG (3) 10 - 14 30 - 40
530015882 SPRING/HSG RET. (1) 6 - 19 8 - 12

530015875 NOSE CLAMP 10 - 24 25 - 35

SHROUD & TANK

530015810 SHROUD/CRANKCASE (4) 10 - 24 40 - 50
530015934 SHROUD/FAN HSG (10 10 - 14 30 - 40

53015886 TANK/SHROUD (2) 10 - 14 40 - 50

LOWER END

530047905 HUB/DRIVESHAFT (1) 5/16-24 70 - 90
530016273 THROTTLE/HSG 8-16 10-15

USE LOCTITE 242 ( MEDIUM STRENGTH) OR PERMA-LOK MM 115.

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2. SUMMARY OF ENGINE SPECIFICATIONS

A. COMPRESSION (COLD ENGINE AFTER MOTOR TEST) 110 - 130 PSIG
B. CRANKSHAFT RUN-OUT .004 MAX

(CIRCULAR RUN -OUT @ .400 GAGE DIA)
C. IDLE SPEED 3400 - 4200 RPM
D. WIDE OPEN THROTTLE INTERMITTENT 2/4 TO (AFTER 3 MINUTES

WARM-UP AND MOTOR TEST). JUST CLEAN
2-CYCLE (2/4 MUST BE MAX 1/8 TURN
RICHER THAN POINT WHERE ENGINE JUST
BREAKS INTO A CLEAN 2-CYCLE).

E. IGNITION TIMING (FIXED) 18° - 22° BTDC @ 3000 RPM
F. MIXTURE SCREW SETTING 1 1/2 - 2 1/2 TURNS OUT
G. COIL AIR GAP .010" - .014"
H. SPARK PLUG GAP (RCJ8Y) .023" - .028"
I. CHOKE SHUTTER STAND OFF .004" MAXIMUM

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3. CRANKCASE ASSEMBLY SPECIFICATIONS

A. INSTALL INNER RETAINING RING IN CRANKCASE.
B. PRESS SEAL INTO CRANKCASE WITH SEAL “LIP: ORIENTED TOWARDS

CYLINDER END OF CRANKCASE.
C. INSTALL OUTER RETAINING RING INTO CRANKCASE.
D. PRESS OUTER BEARING (WITH SEAL) UNTIL IT STOPS AGAINST OUTER

RETAINING RING. SEE FIGURE 1.

NOTE: MAKE SURE SEAL SIDE OF BEARING FACES AWAY FROM RETAINING

RING.
E. PRESS INNER BEARING (NO SEAL) UNTIL IT STOPS AGAINST INNER

RETAINING RING ON OPPOSITE SIDE OF RING FROM SEAL.

FIGURE 1

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4. PISTON, CRANKSHAFT, CYLINDER ASSEMBLY SPECIFICATIONS

A. SPECIAL CAUTION NOTES:

1) CARE MUST BE TAKEN TO PROTECT PISTON FROM SCRAPES AND NICKS.

2) ASSEMBLY FIXTURES MUST BE KEPT CLEAN TO AVOID DAMAGE TO THE
PISTON.

3) DO NOT HAMMER OR TAP PISTON PIN INTO PISTON.

4) CRANKCASE MUST BE KEPT FREE OF CHIPS, DIRT, AND DEBRIS
BEFORE AND DURING ENGINE ASSEMBLY.

B. PISTON AND CONNECTING ROD ASSEMBLY

1) INSTALL PISTON PIN RETAINER IN ONE SIDE OF PISTON.

2) ASSEMBLE CONNECTING ROD TO PISTON (SEE FIGURE 2 FOR
ORIENTATION OF CONNECTING ROD ASSEMBLY).

3) PRESS PISTON PIN (NO SPECIAL ORIENTATION) TO PISTON AND
CONNECTING ROD.

4) INSTALL PISTON PIN RETAINER TO OTHER SIDE.

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FIGURE 2

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4. PISTON, CRANKSHAFT, CYLINDER ASSEMBLY SPECIFICATIONS - CON TINUED
C. CRANKSHAFT ASSEMBLY

1) PRESS CRANKSHAFT ASSEMBLY INTO BEARINGS UNTIL SHOULDER OF
COUNTERWEIGHT BOTTOMS OUT ON INNER BEARING. IMPORTANT:
CHECK TO SEE IF RETAINING RING GROOVE IS CLEAR TO ASSEMBLE
RETAINING RING AND CRANKSHAFT TURNS FREELY (FIGURE 3) WHILE
SUPPORTING THE OUTER BEARING COMPLETELY AND ORIENTING
PROPERLY THE COUNTERWEIGHT.

2) ASSEMBLE RETAINING RING INTO CRANKSHAFT GROOVE.

NOTE: CARE MUST BE TAKEN TO DETERMINE WHEN THE SHOULDER OF
THE CRANKSHAFT WILL CONTACT THE INNER RACE OF THE
INSIDE BEARING SO NO EXCESSIVE FORCE WILL BE APPLIED
OVER THE BEARING.

FIGURE 3

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ASSEMBLE TWO (2) SCREWS TO CYLINDER AND CRANKCASE USING LOCTITE ON THE

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4. PISTON, CRANKSHAFT, CYLINDER ASSEMBLY SPECIFICATIONS - CONTINUED
D. CYLINDER ASSEMBLY

1) COAT CYLINDER WALLS, PISTON, AND PISTON RING WITH 30 OR 40
WEIGHT OIL PRIOR TO ASSEMBLY.

2) ASSEMBLE CYLINDER GASKET TO CYLINDER

3) ASSEMBLE PISTON TO CYLINDER USING A RING PROTECTOR

4) TURN CRANKSHAFT TO TOP-DEAD-CENTER. ASSEMBLE CONNECTING ROD
TO CRANKSHAFT ASSEMBLY.

5) FIT CYLINDER TO CRANKCASE.

6)

THREADS.

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5. CARBURETOR, AIR BOX ASSEMBLY SPECIFICATIONS(18cc FEATHERLITE SERIES)

A. ASSEMBLE CARBURETOR ADAPTER GASKET TO CARB ADAPTER (FIGURE 4)
(NOTE GASKET RETENTION POSTS).

B. ASSEMBLE CARB ADAPTER TO CYLINDER WITH TWO (2) SCREWS. TORQUE TO
SPECIFICATION.

C. SLIDE CHOKE PLATE (SIDE WITH THREE DETENTS TO BE FACING AIR FILTER
BOX) INTO AIR FILTER BOX UNTIL ALL THREE HOLES LINE UP WITH THE
HOLES IN AIR FILTER BOX.

D. PLACE CHOKE SHUTTER INTO FILTER BOX MAKING SURE THAT DETENT ON THE
SHUTTER WILL ENGAGE THE THREE DETENTS IN THE CHOKE PLATE (FIG. 5).

FIGURE 4

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FIGURE 5

5. CARBURETOR, AIR BOX ASSEMBLY SPECIFICATIONS - CONTINUED

E. PLACE CARB GASKET TO CARB ADAPTER, MAKING SURE SLOTS IN GASKET
ALIGN WITH PINS ON ADAPTER (FIGURE 6).

F. ATTACH LARGE DIA. PURGE RETURN LINE FROM FUEL TANK TO LOWER ANGLED
FITTING ON CARB (AS VIEWED FROM REAR OF POWERHEAD).

G. ATTACH SMALL DIA. FUEL LINE FROM FUEL TANK TO FUEL INLET FITTING
ON THE CARBURETOR (THE FUEL INLET FITTING IS THE UPPER STRAIGHT
FITTING AS VIEWED FROM THE REAR OF THE POWERHEAD).

H. INSTALL SCREW THROUGH THE CHOKE SPACER (WITH THE FLANGE AGAINST
THE SCREW HEAD), THROUGH WAVE WASHER AND THEN THROUGH THE CHOKE
SHUTTER INTO AIR FILTER BOX. INSTALL OTHER SCREW THROUGH THE
OTHER HOLE IN THE AIR BOX.

I. ALIGN SCREWS IN AIR FILTER BOX THROUGH CARBURETOR INTO CARB
ADAPTER AND TORQUE SCREWS TO SPECIFICATION.

J. IMPORTANT: CHECK CHOKE LEVER MOVEMENT. CHOKE LEVER MUST HAVE
POSITIVE STOP AT ALL DETENTS AND CYCLE THROUGH ALL THREE POSITIONS
OF CHOKE FREELY.

K. POSITION FILTER SUPPORT PLATE INTO AIR FILTER BOX, RAISED CENTER
AREA UP.

L. FIT AIR FILTER FOAM INTO AIR FILTER BOX. THERE ARE TO BE NO GAPS
OR PINCH AREAS AROUND EDGES.

M. INSTALL AIR BOX COVER TO AIR FILTER BOX WITH VERBIAGE TO TOP OF
UNIT. TORQUE (2) SCREWS TO SPECIFICATION.

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