EMAK 63.4 cm3 Workshop Manual

WORKSHOP MANUAL

63,4 cm³ chainsaws

General failures’ analysis

63,4 cm³ chainsaws

General failures’ analysis

Suggested tools

I. Emak tool kit
II. Compression tester: to check thermal group
III. Electronic tachometer: for 2 and 4 stroke engines, measurement range from 100 to 30,000 RPM

I.

III.

p/n 3055125

p/n 001000785

63,4 cm³ chainsaws

II.

p/n 001000392A

Index

General failures’ analysis

1) Performance

a) Compression test
b) Cylinder and piston inspection
c) Decompressor inspection
d) Cooling system cleaning
e) Muffler inspection

2) Fuel system

a) Fuel and fuel filter inspection
b) Fuel system test
c) Tank breather inspection
d) Engine seal test
e) Manifold inspection

3) Ignition system

a) Starter housing inspection
b) Spark plug inspection
c) Spark test
d) Flywheel-coil air gap inspection
e) Flywheel key inspection

4) Oil pump, bar and shock absorber

a) Oil tank breather inspection
b) Oil filter inspection
c) Sprocket/power mate ring inspection
d) Oil pump inspection
e) Chain brake inspection
f) Lubrication and bar maintenance
g) Shock absorber replacement

5) Tuning

a) Air filter inspection
b) Needle valve inspection
c) Carburetor inspection
d) Suggested tools for carburetion setting
e) Carburetion tuning

6) Tightening torques

7) Trouble shooting

a) The engine does not start
b) Low performance
c) Additional problems

63,4 cm³ chainsaws

1) Performance

General failures’ analysis

a) Compression test
b) Cylinder and piston inspection
c) Decompressor inspection
d) Cooling system cleaning
e) Muffler inspection

a) Compression test

• Apply the Emak compression
tester (I) on cylinder. Pull
energetically the rope 10
times

• Verify that the compression
value in not less than 8 bar –
130 psi

• If the value in higher than
8 bar – 130 psi, start
inspection c), if lower, carry
on with inspection b)

I

p/n 001000392A

63,4 cm³ chainsaws

b) Cylinder and piston inspection

• Verify the diamond scoring on piston and the nickel-lining on cylinder. Replace if necessary

• Verify the piston rings wear using feeler gauge (gap max 1,0 mm)

Tightening torque cylinder-screws

1,2 Kgm (106,20 in lb) + Loctite 243

Warning: during assembly

make sure the circlip has
the feet pointing up

General failures’ analysis

Warning:
The arrow on the top of the
cylinder points towards the

exhaust port.

63,4 cm³ chainsaws

General failures’ analysis

c) Decompressor inspection

Verify that the decompressor and the decompression hole on the cylinder is not closed to carbon deposits.
Clean and/or replace if necessary.

63,4 cm³ chainsaws

d) Cooling system cleaning

Blow, with compressed air, cylinder fins, starter
case and flywheel

Important:

•Clean weekly the cooling system. For heavy
duty work, clean it every day

• Use Loctite 243 to tighten plastic component

Tightening toque cover-basement

0,4 kgm (35,4 in lb) + Loctite 243

General failures’ analysis

Tightening torque

Cover

0,4 kgm (35,4 in lb)

+ Loctite 243

63,4 cm³ chainsaws

e) Muffler inspection

If the muffler is blocked or damaged, clean or
replace it

Tightening torque muffler-cylinder

1,0 kgm (88,5 in lb) + Loctite 243

General failures’ analysis

Tightening torque cover muffler-basement

0,6 kgm (52,1 in lb) + Loctite 243

63,4 cm³ chainsaws

Back to index

2) Fuel system

a) Fuel and fuel filter inspection
b) Fuel system test
c) Tank breather inspection
d) Engine seal test
e) Manifold inspection

a) Fuel and fuel filter inspection

• Verify fuel quality odor

• Dismount and check periodically the fuel filter
and the sintered internal filter. In case of dirt or
oxidation, replace it

General failures’ analysis

Sintered
internal
filter

b) Fuel system test

• Apply the pressure gauge at the fuel line. Check
any possible leakage at 0,5 bar

• If the pressure is not stable, it may indicate
worn fuel system or loose at the carburetor
parts

Go to

Carburetor inspection

63,4 cm³ chainsaws

General failures’ analysis

c) Tank breather inspection

• Dismount the breather and check the components

• Apply the pressure gauge (I), supplied with Emak tool kit, at the breather valve and verify the correct

working in both ways. To check the inlet direction use the adaptor (II), supplied with the pressure gauge’s
box, as shown on the photo. Replace or clean if necessary

I

p/n 1043900

Breather sealing test:

0,2 – 0,3 bar

II

Breathing system test:

0,00 bar

63,4 cm³ chainsaws