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SHINDAIW A SER VICE MANUAL
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1. f m U Lu 00 gt 00 lt Section D Ignition Systems Ignition Troubleshooting continued 54 STEP 1 Test spark with an adjustable gap tester Install an adjustable gap tester turn the ignition switch to the run position and crank the engine vigorously Figure 5 8 Jo simulate the higher voltage require ments of a spark plug firing under com pression test for spark at several settings out to gap of approximately 1 4 E f a previously dead ignition now pro duces a strong bluish spark at the tester the trimmer s spark plug is internally shorted and should be replaced WE f there is no spark at the tester or if the spark is weak yellow orange in color or seems to fire only occasionally go to Step 2 STEP 2 Inspect the entire ignition system M Check for broken corroded or damaged wires or connections E Make sure all ignition components are correct and installed properly Use the appropriate Illustrated Parts List as a reference WE Make sure the ignition stop switch is in the ON position or disconnect the switch as shown in Figure 5 9 STEP 3 Test the ignition stop switch Figures 5 9 and 5 10 If not previously disconnected unplug the stop switch and retest for spark as in Step 1 E fa spark now appears with the switch disconnected use the ohmmeter set to low ohms to test the stop switch for intern
2. GRC 08 Inspection Inspection procedures are the same as for other models except that the output shaft and driven gear must be serviced as a single assembly Figure 11 21 Removing the 250 inner bearing 1 00 Shindaiwa Inc 1994 GearcaSes section 11 Models T C 250 disassembly STEP 1 Replace the inner bearings if they All T GQ were removed STEP 2 Hand fit the output shaft and gear assembly to the inner bearing then seat it n firmly with a soft faced hammer Figure ieee STEP 3 Seat the output shaft bearing using the appropriate bearing driver until it bottoms past the internal snap ring groove es Figure 11 23 STEP 4 Install the output shaft snap ring with its sharp edge facing out STEP 5 Gently spread the clamp at the input drive end of the gearcase with a screw driver blade same as in T C 250 disas sembly then hand fit the pinion gear and bearing set into the gearcase STEP 6 Using the appropriate bearing driver and a soft faced hammer seat the pinion gear and bearing set past the internal snap ring groove groove Bearing driver f installation is difficult use a heat gun to expand the gearcase slightly during installation Figure 11 23 Installing the outer bearing STEP 7 Install the pinion bearing snap ring with its sharp edge facing out Inspection STEP 1 Slowly rotate the output shaft by hand and check for excessive d
3. Pressure Testing Figure 2 8 Many Shindaiwa trimmers and brushcutters can be pressure tested with Shindaiwa p n 72174 99200 gauge and block off kit Where applicable the block off plates are installed over the cylinder ports in place of the carbure tor and muffler as shown in Figure 2 8 If the correct kit and or block off plates are not available small sections of heavy rubber Figure 2 8 Pressure testing a crankcase or gasket can be clamped beneath the muffler and carburetor bases Once both ports are blocked a Walbro p n 57 11 or similar gauge can be used to pressurize the crankcase through an adapter inserted in the spark plug hole 16 Shindaiwa Inc 1994 Trou bleshooti Ng Section 2 Seizure Checklist 6 6 Shindaiwa P N 60127 S n dIWa SEIZURE CHECKLIST PLEASE CHECK THE APPROPRIATE BOX RESPONSE 1 Modelo TT serial Number 2 Previous Repair oo ee eeeeecesceesceeseceseeeeeceseseeeceeevaeeversvsnetenetesvenseenees No Yes rs 3 Previous Seizure 2 2 cccccecccsseeeescceeeesceeeeccsaeescoeeeeccuseeccseeescceeeesceees No Yes _ A Gasoline Grade ae ee ee aa DAN anane kan a N E ga eee a a a ene e ng naa Regular _ im Unleaded ys Unleaded Premium LI O o
4. SERVICE MANUAL Shindaiwa Grass Trimmers _ Grass Trimmers Brushcutters and Lawn Edgers Service Manual Shindaiwa Grass Trimmers Brushcutters and Lawn Edgers Contents Section page 1 Model Designation and Identification 2 2 Troubleshooting cccc eee 8 3 Carburetors eaaa 18 General MATORNIAUON serii 18 Troubleshooting Carburetors 20 TIK AI DUNGO sasaged ap ababe naga pade a An 25 Walbro Carburetors aaa aa anane 34 4 Recoil Starters aana 44 5 Ignition Systems ee 50 6 Clutches and Flywheels 58 7 Cylinders and Pistons 64 8 Engine Crankcase 2 9 Mufflers eaaa aaa aaa eaaa eea rene 80 10 Mainshafts and Outer Tubes 84 11 GearcaSeS teee eee 94 12 Lawn Ed gers aana 102 13 Appendix aaa eaaa eaaa aana neran 104 SDCCIHICAONS sasa ag Tak Anaa aa E aaa 104 TONYUS VAN SS espensierat 108 Tolerances and Wear Limits 110 ESAK saga asa aia a aa E NE TAN D AGE a Ka 112 Metric Conversions aranana aee 114 Special Service Tools sa rrrrenne 115 Shindaiwa Inc 1994 1 Attention Statements Throughout this manual are special attention stat
5. Excessive vibration ADDITIONAL PROBLEMS Possible Cause Clogged air filter Muffler is clogged Clogged fuel filter Carburetor mixture IS incorrect Idle speed set too low switch is turned off Fuel tank empty Clogged fuel strainer Water in the fuel shorted spark plug or loose terminal Ignition failure Piston seizure Ground stop wire is disconnected or switch is defective Overheating due to incorrect spark plug Overheated engine Engine idle soeed is set too high Broken clutch spring or worn clutch spring boss Loose attachment holder Warped or damaged attachment Loose gearcase Bent main shaft worn or damaged bushings Remedy Clean the air filter Refer to the Carburetor Section Decarbonize Refer to the Muffler Section Replace the fuel filter Carburetor Section Adjust carburetor Carburetor Section Adjust Refer to the Specifications Section Reset the switch and re start JJ O Cc W m 0 zE O O lt Refuel Replace strainer Drain replace with clean fuel Clean or replace spark plug tighten the terminal Refer to the Ignition Section Refer to the Cylinder and Piston Section Test and replace as required Ignition Section Correct plug Champion CJ8 Ignition Section Idle engine until cool Find cause of overheat set idle See The Specification Section Replace spring shoes as required check
6. Rotary valve assembly Metering valve Figure 3 25 Walbro WZ Carburetor used on Shindaiwa I 20 grass trimmers to serial number 0089960 Shindaiwa Inc 1994 41 U am O H Lu CC aa lt O Section 3 Walbro Carbu retors Walbro WZ Carburetors continued 42 B Primer Systems The WZ carburetor uses a primer system instead of a conventional choke valve The system draws fuel during routine air purge operations and includes a starter box a starter button a wick and several check valves For engine startup the flow sequence is as follows 1 Squeezing the purge bulb diverts a me tered quantity of fuel to the WZs primer Circuitry WE Most of this fuel is stored under pressure in a chamber connected to the starter box HA small amount of fuel also passes through a check valve and is injected into the venturi through the main nozzle 2 Pressing the starter button allows fuel stored at the starter box to saturate a porous foam wick located just inside the carburetor bore 3 During cranking the raw fuel injected at the carburetor nozzle is immediately drawn into the engine s crankcase and combustion chamber 4 As the engine starts air entering the carburetor bore becomes saturated with fuel from the starter wick 5 As the starter wick runs out of fuel the engine warms and no longer requires a fuel rich mixture Shindaiwa Inc 1994 Walbro Carburetors section 3 Trou
7. Avoid engine overheat damage Fuels containing alcohol or other oxygen bearing Compounds can increase engine operating temperatures When a 2 cycle engine must be operated with CAUTION Operating a 2 cycle engine at peak rom lean mixture can Cause permanent engine damage from overheating oxygenated fuel you must compensate for the additional oxygen by slightly enriching unscrewing the high speed adjustment screw Additional information on oxygenated fuels is provided in the Fuel and Oil Section of the Appendix Shindaiwa Inc 1994 33 U am O H Lu CC aa lt O Section 3 Walbro Carbu retors Walbro Carburetors Basic Adjustment Figure 3 19 34 Basic Adjustment The Walbro carburetor contains no separate internal circuitry for idle soeed operation When servicing the Walbro carburetor adjust idle soeed mixture by raising and lowering a threaded fuel needle in the center of the carburetor s rotary barrel valve E Make initial settings by completely remov ing the needle in a counterclockwise direction then reinstalling it to the specifi cations listed in the Appendix E Make fine adjustment in 1 8 turn incre ments with the engine warmed to normal operating temperature Rotating the needle in and then out to locate a position midway between lean idle and rich idle opera tion Walbro high speed adjustments vary by model Make adjustments either by t
8. Inner bearing Shaft Collar Output Outer Snap gear bearing ring Figure 11 1 This Shindaiwa gearcase assembly uses four ball bearings in a cast aluminum housing with machined bearing bores Figure 11 2 Removing the shaft collar Figure 11 3 Removing the snap ring from the output side of the gearcase NOTE Models 1 18 T 20 T C 230 T C 250 and later series T C 27 require removing the gearcase output seal before removing the output side snap ring M Jo remove the output seal from these models use a pick or small screwdriver to pry the seal from the gearcase Figure 11 4 On models with the output seal installed beneath the snap ring the seal is normally removed with the output shaft and bearing assembly CAUTION When removing seals avoid damaging gearcase bearings beneath Output Shaft and Bearing Removal STEP 1 Thread the appropriate puller bolt completely into the puller body Figure TES STEP 2 Thread the shaft puller bolt into the gearcase output shaft turn counter clockwise until the puller body bottoms against the gearcase STEP 3 Continue turning the puller bolt until the output shaft and bearing assembly are completely free from the gearcase housing NOTE If the shaft is difficult to remove use a heat gun to pre heat the gearcase to approximately 212 F 100 C Pinion and Bearing Removal STEP 1 Use snap ring pliers such as Snap On p n PR 23A or
9. T L U am Lu H lt H 00 O O Lu CAUTION The starter hub is also threaded onto the engine crankshaft Never use pullers or prying tools to remove the starter hub STEP 3 Unscrew the starter hub counter clockwise all models and remove it from the crankshaft IMPORTANT Some starter hubs contain an internal ratchet or pawl Before further disassembly of these Figure 4 4 Locking the hubs note the location and orientation of the engine crankshaft with a starter pawl spring and pawl retainer plastic piston stop or a length of starter cord 46 Shindaiwa Inc 1994 Recoil Starters section 4 Inspecting the E Inspect the hub for cracks fractures or Hub other damage Replace if noted E Inspect the pawl where used for wear at contact surfaces and attachment points Replace if you detect damage or measur able wear E Inspect the pawl return spring Replace if bent or otherwise distorted STEP 1 Install the pawl where used in the reverse order of removal IMPORTANT Pawl installation is designated L or R to Installing the Hub Pawl in right hand hole Pawl in left permit engagement for counter rotating hand hole engines Starter pawls must be installed in the exact orientation as removed Figure 4 5 Some hubs can be reversed for cranking counter rotating engines STEP 2 Install and tighten the hub assembly securely Figure 4 5 Starter pawl ins
10. 03937 in Gm 20937 in Cin 0320 ft meter 3 28 ft km 621 mile cc 061 Cu In liter 61 02 Cu in ml 0338 fl oz liter 33 81 fl oz liter 264 gal Oli 0399072 kg 2 2 Ib kg cm 868 in Ib n m 8 844 Ib kg m 7 28 ft Ib iS 7 OF TLD kw 1 34 hp SAE hp DIN 1 104 hp SAE psi 9836 hp SAE bar 14 5 psi kpa 145 psi kg sq cm 14 22 psi C to F Temperature in C x 9 5 1 8 32 1 1 km hr 625 mph km liter 2 35 mpg Appendix Special Service Tools section 13 Engine Tools Flywheel Puller Assembly 20000 96104 Piston Pin Puller Assembly all models 20021 96601 Assembly Included with assembly M 20000 96631 Guide pin M 20035 96630 Guide pin M 20021 96630 Guide pin M 20021 96650 Pin adapter M 20021 96660 Pin adapter M 20021 96670 Pin adpater Flywheel Holder 20000 9641 1 Outer Tube Bushing Driver All models Gearcase 22000 96101 Tools T 18 T 20 T C 230 M 22035 96500 Puller M 22035 96600 Puller M 22035 96210 Driver M 22035 96310 Driver M 22035 96410 Driver For T C 250 use 22000 96521 puller bolt with 22035 96510 holder T C 25 T C 27 M 22000 96510 Puller M 22000 96600 Puller M 22000 96210 Driver M 22000 96310 Driver M 22000 96410 Driver gt U U m Z U v m a gt m 00 m JJ O m O O C 35 B 40 B 45 RC 45 22015 96510 Holder 22015 96520 Bolt 22015 96600 Puller Assembly 22015 96
11. Cylinder to Carb Insulator 5mm 44 52 50 60 44 52 50 60 35 44 40 50 44 52 50 60 Flywheel 8mm 104 122 120 140 104 122 120 140 175 218 200 250 175 218 200 250 10 mm Starter Hub on Crankshaft 8mm 104 122 120 140 104 122 120 140 105 120 120 140 105 120 120 140 Muffler 5mm 52 70 60 80 52 70 60 80 6 mm 80 90 90 100 90 105 100 120 spark Plug 14mm 148 165 170 190 all models Clutch Shoe Bolt 6mm 60 90 70 100 all models Coil 4mm 35 44 40 50 35 44 40 50 44 52 50 60 44 52 50 60 Unit 4mm 17 26 20 30 17 26 20 30 Cylinder Cover amp Recoil Starter 4mm 26 44 30 50 26 44 30 50 5mm 26 35 30 40 26 35 30 40 Carburetor 5mm 35 44 40 50 TRIMMER BRUSHCUTTER ASSEMBLY Gearcase to Outer Tube 5 mm 6mm 52 78 60 90 52 78 60 90 90 105 100 120 90 105 100 120 Handle Bracket 5mm 52 60 60 70 all models AS 6mm 87 104 100 120 all models z Clamp Outer Tube 5mm 52 60 60 70 all models g Blade Holder 7mm n 8mm 104 120 120 140 i 10 mm 175 190 200 220 175 190 200 220 Trimmer Head 7mm Cc 8mm m Fan Cover 5 mm 44 60 50 70 Screw Locking Agent Recommended Three Bond 1401 m Screw Locking Agent Recommended Three Bond 1360 00 Shindaiwa Inc 1994 111 O m Z lt zi TT D D x a TT A 0 lt Section 13 Appendix Fuel and Ol Gasoline What you need to Know about today s motor fuels i CAUTION Under certain conditions so
12. Flywheel Cylinder Fins wicndaicrivanicecawennnsecurirwasd ater ucts vers Sunnsateanxecitaeinays Clean Damaged Debris Clogged 18 Cylinder Crankcase Bolts ccccccccseececseececeeeceeceeeeeseeeeesaaeeesaeeees Tight LL Loose 19 Impulse Line if equipped naa ceccceececeeeeceeeeceeeceeeeseesseessaees Intact Torn _ Clear Plugged Li 2o lal 2 cae eee eet rane Cr ene oe ee on eee nee ee eee ree eee eee cree ae Clean _ Dirty Plugged 21 Fuel Line pressure check aceccne cit icesees tose nancospeineaatesiasetnahcoiwadcaccetodicenductensncseenewnlegseaie OK Torn Leaking 22 Carburetor Inlet Screen sadsceccaccssncondesnadacesxsevednewsaaaestansndetadeaesdneteseen Clean _ Dirty 23 Bo oVinsulator BIOGk sasaadosan angan areata Naane aaa AS AE gan Na KAG a Aa a Ga gawa a aab daa baan Ga Intact Torn Cracked 2A TUE WG anaa saga alian aa a a anda gana E EE EE EN Clear Plugged 25 Crankcase Cylinder Pressure Check 6 psi ccccsscccceeeeeceeseeeeeseeeceseeeeeeseesseeeeees OK Excessive Leakage _ Shindaiwa Inc 1994 1 7 U am O H Lu CC aa lt O Section 3 Carburetors General Information Introduction Operational Comparisons 18 A carburetor s only function is to mix air and fuel to accommodate any combination of engine load and rpm All current model Shindaiwa trimmers and brushcutters use either a Walbro rotary va
13. STEP 1 Remove the metering lever retaining SCrew STEP 2 Carefully remove the control lever pin and spring STEP 3 Withdraw the inlet needle Be especially careful not to damage the needle s Viton tip 26 Shindaiwa Inc 1994 TK Carburetors Section 3 D Main Jet Unscrew the main jet holder and remove the main jet NOTE The main jet on model DP N is not removable When removing the one piece jet and O ring used on early model DP series carburetors the O ring may require have to be removed separately from the carburetor body Figure 3 12 E Fuel Pump STEP 1 Remove the fuel pump cover screws E P and lift off the pump cover Eh m Carefully note any springs beneath the Slide valve fuel pump cover how they are used and and needle oriented not applicable on all models assembly z e High speed NOTE oe mixture o Fuel inlet If the cover is difficult to remove it can usually screen ve be loosened by cocking it a soft jawed vise N m STEP 2 Note the orientation of any alignment Fuel pump a tabs protruding from the pump diaphragm assembly D and gaskets Use the IPL as a reference STEP 3 Gently peel the diaphragm and gaskets from the pump body depe adjustment F Adjustments STEP 1 Remove the idle stop screw using a Metering counterclockwise rotation cabal Check valve assem STEP 2 Remove the idle stop spring and the a gssembi high speed needle valve On
14. by substitution Figure 5 13 Unplug the unit at the harness and tempo rarily connect a new unit Retest for spark as in Step 2 E if a spark now appears the original TCI unit has an internal problem and must be replaced Disconnect TCI and ignition switch during testing Jumper Lead Figure 5 13 Testing the TCI unit by substitution 2 piece ignitions only Q O Z lt m 00 Shindaiwa Inc 1994 55 U Lu 00 gt 00 lt Section D Ignition Systems Ignition Troubleshooting continued Notes on the Use of Ignition Analyzers General Troubleshooting Procedures 56 STEP 7 Test primary and secondary magneto windings two piece ignition for continuity M lest primary coil resistance and compare with new parts Figure 5 14 M lest secondary coil resistance and com pare with new parts Figure 5 15 An ohmmeter reading of either O or infinity for open circuit and abbrev during either test indicates the coil is internally faulted and must be replaced STEP 8 Test coil module one piece ignitions secondary magneto windings for continuity as in Step 7 E f the secondary coil resistance value appears normal repeat Steps 3 and 4 nternal connections between the primary windings and the integrated TCI make further ohms testing impractical and unreliable A modular coil that fails to spark after performing S
15. called oxygenated motor fuels can raise engine combustion chamber temperatures beyond acceptable limits and can lead to catastrophic engine failure Oxygenated Fuel Under the provisions of the Federal Clean Air act of 1990 gasoline sold in thirty nine U S cities and metropolitan areas is now blended with an oxygen bearing compound on at least a seasonal basis The most common oxygenates in use contain either alcohol or an ether additive since both alcohol and ether contain oxygen an engine burning either compound has a hotter rate of combustion and therefore fewer exhaust emissions some states require that the use of oxygen ates be posted at the pump Ethanol alcohol is a commonly used oxygenate and may contain as much 35 oxygen Ether based compounds contain about 18 oxygen and are often marketed as MTBE TAME or ETBE IMPORTANT Ether obased compounds contain approxi mately one half the oxygen contained in ethanol and are usually less damaging to a two cycle engine Octane Rating Igniting a fuel within a cylinder causes a rapid expansion of burning gasses This expansion is what forces the piston to move down the cylinder to transfer energy to the crankshaft However fuel with a low octane rating can ignite violently detonate in a high compres sion engine and may produce cylinder pressures 2 to 3 times higher than normal engine design limitations Such pressures have a hammering effect on
16. engine E if voltage is noticeably lower check for briskly proper air gap and ground connections see Steps 1 and 5 under Ignition Trouble shooting E Two piece ignition f primary voltage is still low test the TCI unit by substitution Step 6 Ignition Troubleshooting HM One piece ignition f primary voltage continues to read low after checking ground connections and air gap replace Figure 5 18 Testing voltage required to fire the plug ae Adjustable gap the ignition coil J pa ea Flywheel When available a flywheel simulator can be Simulator very useful for performance testing individual ignition components or basket case ignition Flywheel systems simulator Ignition coil To duplicate the engine s moving flywheel being tested magnets the simulator generates a pulsating magnetic field that permits testing of indi vidual components of any magneto based ignition system Figure 5 19 O O V lt f m V To power source IGN 11 Figure 5 19 Using a flywheel Simulator Shindaiwa Inc 1994 57 section Clutches and Flywheels Direction of General All Shindaiwa trimmers and brushcutters use Rotation a centrifugal clutch mounted on the engine flywheel rotor Clutch shoe facing is either bonded or metal and shoes are retracted by one or more coil springs hooked between the shoes As RPM increases centrifugal force overcomes spring tension and forces the
17. oO 0 H LL lt zE 00 lt section 10 Mainshafts and Outer Tubes Troubleshooting Vibration Problems J2 NOTE A logical and systematic approach is essen tial when troubleshooting vibration com plaints Begin by defining the type of vibration and especially the rom range where vibration occurs A low rom vibration or chatter that disappears on acceleration for example may be nothing more than normal clutch engage ment On the other hand legitimate vibration complaints may not be completely or perma nently solved by simply replacing parts at random Shindaiwa Inc 1994 All Units M Check the outer tube for damage Inspect the mainshaft for burning discoloration straightness see Shindaiwa Service Bulletin SB 31 Verify bushing alignment by inserting a known good mainshaft while holding the tube vertically The mainshaft should pass through the bottom three bushings without stopping Check the powerhead rotor for debris or damaged missing fins Damaged or glazed clutch shoes may chatter and vibrate Check for damaged springs worn boss area correct shoe orientation Trimmers When using a T C 25 with a trimmer head always remove the safety clip from be tween the blade holders Arbor bolts can be bent from improperly advancing the line during operation Check for accumulated debris packed around attachment base or holders Check for proper line size and leng
18. sure they are not plugged 3 Inspect the check valve Make sure itis assembled arrestor is not plugged or gummed with dirt or debris Adjust the carb correctly 9 Check the condition of the 4 Check the filter element spark plug Section 5 ne eG Or eS aana D 40 Mak a en Na leaks by performing a 5 Inspect the air filter ake sure the lank IS nile pressure test page 16 with clean fresh fuel mixture 6 Check the insulator block see the Appendix for air leaks or blockages U am O H Lu CC aa lt O 5 7 A a We 8 A O EL Spee Dak EP 2 12 1 any 10 Figure 3 3 Carburetor Troubleshooting Guide 20 Shindaiwa Inc 1994 Troubleshooting Carburetors section 3 Fuel Tank Lines Test the tank vent for proper operation To AE e Ah and Filters E Inspect fuel lines for signs of deterioration tank and must be oriented or leaks If in doubt remove fuel line and as shown pressurize with a Walbro tester WH Consult the current Illustrated Parts List W A IPL to verify the requirement and proper Fuel line n i installation of an in line check valve Figure P 3 4 Check valve retainer A properly installed check valve should Check permit free passage of fuel toward the fuel alve Check valve body Figure 3 4 Check valve assembly TK shown tank but very slow passage in reverse M Verify correct filter components and installation through the current IPL
19. 1500mm 1500mm 1500 mm Flex Solid Flex Flex Solid 1 piece splined Cable 1 piece splined Cable 6 mm 6 mm 6 mm 6 mm 6 mm 6 mm 6 mm 6 mm mm mm 6 mm 1262mm 1495mm 1393mm 1588mm 1545mm 1495mm 1495mm 1540mm 1545mm 1545mm 1540 mm Liner 4 Liner Liner 4 5 5 Liner 5 5 Liner Yes Yes Yes Yes Yes Yes No Yes Yes No Yes No No No No No No Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No No No Yes Yes No No No Yes Yes Yes Yes Yes Yes Yes 8 6 3 9 94 43 106 48 10 8 49 9 75 44 95 43 101 46 11 9 54 11 50 11 5 5 2 12 3 5 6 Shindaiwa Inc 1994 1 O05 gt V v m Z z i 0 L m a gt a O Z T section 13 Appendix Specifications Se it ca ed T 25 C 25 T 27 C 27 C 35 BP 35 B 40 B 45 RC 45 ENGINE Displacement cc cu in 24 1 1 5 24 1 1 5 21 2h lat 2b 2 lef 33 6 2 1 330 21 39 4 2 3 41 5 2 6 41 5 2 6 Bore stroke 32x30 32x30 34x30 34x30 36X33 36x33 39x33 40x33 40x33 Horsepower 1 4 1 4 1 5 1 5 1 8 1 8 2 3 2 33 230 RPM maximum hp 8 500 8 500 7 500 7 500 7 500 7 500 8 000 8 000 8 000 Maximum no load RPM 11 500 11 500 11 500 11 500 11 500 11 500 11 500 11 500 11 500 Weight Ib kg 12 3 5 6 anar 12 3 5 6 123 9 14 1 6 4 20 5 9 3 16 8 7 6 17 8 8 1 17 9 8 4 Power weight hp Ib 8 8 8 9 8 2 8 3 78 11 4 lo 7 6 22 Specific output cc per hp 17 2 17 2 18 1 18 1 18 7 18 7 17 1 17 8 27 Idle RPM 100 3 000 3 000 3 000 3 000 2 150 2 150 2 150 2 150 2 150 Clutch engagement rpm 250 4 500 4 500
20. 25 TK Slide DP10W T 27 TK Slide DPV10W T C LE 230 Walbro Rotary WYL 19 T C LE 250 TK Slide DP N10W C 20 early Walbro Rotary WZ8C C 20 late TK Slide DPV10W C 25 TK slide DP10W C 27 TK Slide DPV10W C 35 TK Slide DPVIIW BP 35 TK Slide PCIOHW B 40 TK slide DPW13 B 45 TK slide DPW12 RC 45 TK Slide DPW12 SYOLAYUNEEVD Shindaiwa Inc 1994 1 9 section Troubleshooting Carburetors Troubleshooting Mechanical failure of any carburetor is far less IMPORTANT common than problems resulting from con Carburetor operation is directly affected by the taminated fuel improper adjustment or quality of air and fuel entering the carburetor operator abuse Figure 3 3 is provided as a Before troubleshooting or adjusting any troubleshooting checklist The following carburetor inspect fuel and air filters for pages of this Section provide additional cleanliness operation and proper installation details about these troubleshooting steps Troubleshooting requires a systematic search for anything that might prevent the proper quality and mixture of fuel and air from entering being ignited in the combustion chamber and then expelled through the exhaust This means starting from both the fuel tank and air cleaner and then working inward until the source of the problem is discovered Inspect the tank vent 7 Check engine compression 11 Inspect carburetor 2 Inspect fuel lines Section 7 passages or valve Make 8 Make sure the muffler
21. 4 500 4 500 3 800 3 750 3 700 3 800 3 800 Crankshaft 3 piece with pressed in crankpin all models Crankshaft bearings Ball bearings all models Conrod Forged 1 piece all models Conrod bearing large end Caged Needle Bearing all models Conrod thrust control Small End of Conrod all models Piston Forged aluminum all models Rings 2 2 2 2 2 2 2 2 2 Cylinder Chrome plated Open transfer Ports all models Crankcase pressure test 4 to 6 pounds maximum no loss over a 3 minute test all models SE FUEL SYSTEM eR Carburetor TK TK TK TK TK TK TK TK TK r Model DP10W DP10W DPVIOW DPVIOW DPVIOW PCIOHW DPW13 DPW12 DPV 1W 1E SR Primer Air Purge Primer Primer Primer Primer Primer N A Primer Primer Primer Adjustment H 2 1 4 2 1 4 2 1 4 2 1 4 2 N A 2 3 4 2 1 2 3 2 1 4 tm Adjustment L 0 1 2 0 1 2 0 1 2 0 1 2 1 2 N A 3 4 1 2 1 4 7 Mounting method Captive Nut Insulator Block all models im Filtration Oiled Foam Element all models x Tank location relative to engine Under Under Under Under Under Top Top Under Under Tank Mounting System Bungee Bungee Cushion Cushion Bungee Bungee Bungee Bungee Bungee rug Number of Elements 2 2 3 3 2 2 2 2 2 Tank Capacity cc ounces 700 24 700 24 660 22 7 660 22 7 1 000 34 1 200 40 6 1 100 37 2 1 000 34 1 000 34 Fuel Vent Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Vent location Tank Tank Tank Tank Tank Cap Cap Tank Tank Recommended fuel Unleaded Regular all models Fuel oi
22. 6 2 Clutch assemblies 58 Shindaiwa Inc 1994 Lu Lu IE LL Lu T O H O Clutches and Flywheels section 6 Clutch Shoe Orientation Clutch Removal see Figure 6 2 Clutch shoe orientation determines whether initial clutch engagement occurs at the leading or the trailing portion of a clutch shoe s contact surface Figure 6 3 WE A clutch installed in the leading position usually provides the fastest engagement with the least slippage at lower engine speeds but may produce some slight Chatter during initial engagement WE A clutch installed in the trailing position allows slower and therefore smoother shoe engagement but can be vulnerable to abusive low rom operation associated with excessive trimmer line length and some tree blades Shindaiwa trimmers and brushcutters will generally deliver best performance and longest clutch shoe life when clutch shoes are installed in the factory recommended orientation listed below Models With 2 Shoe Clutch STEP 1 Lock the flywheel in position with clutch tool p n 20000 96411 Figure 6 4 or use a Soft piston stop or short length of starter cord as shown in Figure 6 5 STEP 2 Use a socket wrench to remove the two clutch shoe shoulder bolts Note the position of the spacer washers between the clutch shoes and flywheel mounting bosses Models With 3 Shoe Clutch STEP 1 Use pliers to remove 3 clutch springs STEP 2 Use a soft
23. 810 0170 4 spring retainer for excessive wear or SS S _ cracks Replace if noted IMPORTANT E Inspect the recoil body and mounting lug Dimensions do not allow for compression areas for cracks or other damage Replace diameter or stretch length if noted Lubrication Lubricate the recoil spring and recoil housing center post with a thin film of Shindaiwa Premium Gearcase Lubricant or equivalent Shindaiwa Inc 1994 4 U am Lu H lt H 00 O O Lu section 4 Recoil Starters Reassembly General 48 Recoil Spring Cassette Carefully install a new Shindaiwa recoil cassette assembly in the starter housing Recoil Spring Retainer STEP 1 Grasp the spring with a needle nose pliers and carefully remove and discard the outer retaining wire new spring only Figure 4 6 STEP 2 Replace the spring in the reverse order of removal Align the spring s outer end loop in the appropriate notch on the recoil housing or reel Hold the spring in place while slowly releasing it with the pliers NOTE If the spring escapes it can be rewound inside the lid from a baby food jar or similar small diameter appliance Install the Cord STEP 1 Replace the cord on the reel using a a stopper knot Figure 4 7 STEP 2 Wind the cord on the reel in the reverse order of removal but leave the last 6 to 8 inches of cord exposed and hanging from the reel notch Figure 4 8 Install the Reel ST
24. Cable E Shindaiwa models F 18 F 20 F 21 and Trimmers F 230 all use a flexible mainshaft cable Figure 10 8 turning in a flexible plastic liner E Model BP 35 features a unique combina tion of a flexible shaft spliced to a rigid mainshaft assembly E All flex shaft cables have a piano wire core surrounded by a multi layered piano wire outer wrapping M The cable diameter on all curved shaft trimmers is 6 mm The flexible drive cable used on model BP 35 is 8 mm in diameter gt Z 2 gt TI 2 GC W m 00 Figure 10 8 A Shindaiwa flex shaft trimmer E An aluminum alloy outer tube is standard F 18 shown on all models except F 20 which uses a steel outer tube Shindaiwa Inc 1994 89 00 Lu m U H LL lt zE 00 lt section 10 Mainshafts and Outer Tubes Typical Cable Maintenance Except BP 35 BP 35 Maintenance 90 STEP 1 Remove the shaft case housing index bolt and loosen the clamp bolt Figure 10 9 STEP 2 Remove the shaft case housing and withdraw the flexible shaft STEP 3 Clean the flexible shaft in solvent and recoat its entire length with Shindaiwa Premium Gearcase Lube STEP 4 Reinstall the flexible shaft in the tube housing To insure full engagement with the powerhead rotate the flex shaft slowly during installation STEP 5 Fill the shaft case housing with fresh grease and reinstall it on the shaft tube If necessary rotate t
25. all models 012 014 3mm all models Transistorized advance Champion CJ 8 Champion CJ 8Y Chmp CuJ 8 NGK BM6A all models 025 6mm all models 1 piece 1 piece 1 piece 1 piece 1 piece 3 3 3 3 3 Yes Yes Yes Yes Yes No No No Yes Yes Yes N A Yes N A N A Yes Yes Yes Yes Yes Gearcase all models 1 299 1 235 1 Tao 1 357 1 1 997 6061 T6 Aircraft Alloy Aluminum Extruded and Drawn all models 26 mm 26 mm 26 mm 26mm 28 mm 1 5mm 1 5mm 1 6 mm 1 6mm 2 0 mm 1500 mm 1500mm 1 00 mm 1500mm 1400 mm Splined solid 1 piece Mainshaft 7mm mm mm mm 8 mm 154 mm 154 mm 1547 mm 154 mm 1452 mm 5 5 5 5 5 Yes No Yes No No No Yes No Yes Yes Yes NO Yes NO NO NO Yes NO Yes Yes Yes NO Yes Yes NO Tube Yes 12 3 5 6 1490 12 3 5 6 123 0 14 1 6 4 BP 35 B 40 B 45 RC 45 Chmp CJ 8 Chmp CJ 8 Chmp CJ 8 Chmp CJ 8 Sealed 1 piece with Spark Arrestor Screen 3 3 No Yes No Yes N A N A N A Yes 1 2351 t391 26 mm 28 mm 1 5 mm 2 0 mm 1318 mm 1400 mm Splined 1 piece 70mm 8mm 1402 mm 1451 mm 4 5 Yes No No Yes Yes No No Yes Tube No Yes 20 5 9 3 16 8 7 6 Shindaiwa Inc 1994 3 3 Yes Yes Yes Yes N A N A Yes Yes 1 05771 hoot 28mm 28 mm 2 0 mm 2 0 mm 1400 mm 1400 mm splined 1 piece Hollow 10 mm 10 mm 1451 mm 1451 mm 5 5 No No Yes Yes No No Yes Yes No Grip Yes 17 8 8 1 107 gt v v m Z z i 0 v m a gt a O Z T Section 13 Appendix Oro Ue Values Bolt Values
26. and inspect the filter element for dirt and debris Figure 3 7 CAUTION nn Dirt or other debris on the inner o i i lt ka filter screen may indicate addi tional debris is trapped within the carbure tor body Trapped debris can restrict fuel flow possibly leading to engine seizure SYOLAYUNEYVD IMPORTANT Most TK carburetors do not contain an internal fuel filter or screen Dirt or debris D entering these carburetors will frequently Metal Screens lodge beneath the inlet needle or within the OK high speed jet s 4 Th ea sg CAUTION Ans Use the specified fuel filters only er The modification substitution or en use of aftermarket fuel filters or compo 2 4 4 nents can result in an unbalanced fuel Some early model Walbro filters used as flow within the entire system and may an inner element that resembled grey wool or felt This inner element should be replaced with a pair of metal screens p n 22118 85460 cause engine performance problems Figure 3 5 Exploded fuel filters typical Shindaiwa Inc 1994 21 section 8 Troubleshooting Carburetors Air Filters All Shindaiwa trimmer brushcutters use oiled foam air filter elements Apply oil here M Consult the current Illustrated Parts List B IPL to verify correct components and J a installation Discard any distorted or deteriorated filter components T LOON C gt A clogged but otherwise serviceable foa
27. base Arrestor retaining screw Gasket Muffler Gasket Lockwasher bee G ane Gasket Muffler Spark arrestor Gasket Pii Muffler Spark arrestor Lo Gasket and Spark arrestor a WA cover Gasket Wa 0 dS 14S nin Cover Screw Screw Figure 9 1 Shindaiwa muffler systems typical Muffler Removal To inspect for carbon buildup at cylinder exhaust ports remove the muffler from the powerhead by unscrewing two mounting bolts and a single support bolt where used located at the base of the muffler Figure 9 2 Mounting bolts CAUTION Never decarbonize cylinder ports while the cylinder is assembled to the engine Dislodged carbon deposits may enter the engine causing severe mechanical damage See Section 7 for a cylinder decarbonization procedure Figure 9 2 Muffler mounting systems Shindaiwa Inc 1994 81 Section 9 Mufflers Reassembly Muffler Installation STEP 1 Use a scraper to carefully clean the mating surfaces on both the muffler and cylinder flange CAUTION Do not allow carbon or other debris to enter the engine STEP 2 Install the two muffler bolts through the muffler and place a new Shindaiwa muffler gasket over the bolts CAUTION FIRE HAZARD Never operate a trimmer or brushcutter with a missing or leaking muffler gasket CAUTION The muffler gasket is an integral part of
28. clutch shoes against the inner surface of the cH12 clutch drum Figure 6 1 Figure 6 1 Typical clutch assembly The flywheel casting is indexed to the engine crankshaft by a machined woodruff key slot Centrifugal force overcomes spring tension and forces the clutch shoes against the drum Shoe Two shoe system Shoulder bolt Clutch M Iwo shoe clutches are used on all units up Washer Figure 6 2 E hree shoe clutches are used on models C 35 B 45 and RC 45 M Model B 40 and earlier models of C 35 were manufactured with a metal shoe clutch with four shoes Spring P Although some clutch components are Springs interchangeable between models always verify that substitutions are identical in weight Three shoe system and dimensions to the parts being replaced LAN Gilar Avoid random substitution of clutch J bolts springs spring length rate gauge and Shoe number of coils must all be accounted for gt Refer to the table at the bottom of the next ir page for clutch interchange information IMPORTANT Part numbers are subject to revision When ordering replacement parts always consult the current IPL Illustrated Parts List and applicable Parts Revision Notices CAUTION H Four shoe system ALWAYS replace clutch shoes as an assembly NEVER attempt to replace a single shoe or a portion of a amp set Partial clutch replacement can cause trimmer vibration Plate C Body Figure
29. freely but fails to engage make sure the starter pawl and spring move freely Also make sure the starter pawl and spring are properly oriented for your model trimmer or brushcutter WE f the the starter binds on either extension or retraction verify correct line diameter E Make sure all components are properly oriented beneath the starter post center SCrew Shindaiwa Inc 1994 49 Section 9 Ignition Systems Theory of The TCI unit operates as a normally closed Operation grounding switch that allows current to flow within the magneto s primary coil windings whenever the engine s flywheel magnets approach the coil This current flow generates powerful electromagnetic flux lines that surround both the primary and secondary magneto coils Figure 5 1 The primary coil voltage driving this current flow peaks at approximately 200 volts as the magnets move past the coil Expanding magnetic field Primary coil Current flows S H V AN 5 AJ fN y Y tt TT TCI closed y 4 4 an tt A Xi oe ee ee 8 fi Secondary coil 00 Lu 00 gt 00 lt Flywheel Figure 5 1 Acting as a switch the normally closed TC allows the moving flywheel magnet to generate a flow of current in the primary coil The current flowing in the primary windings generates a powerful magnetic field that surrounds both coils DO Shindaiwa Inc 1
30. hole completely through the piston crown Heat causes the piston to expand and score at the exhaust side sticking rings in their grooves Figure 2 6 Damage caused by preignition Detonation results when fuel explodes instead of burning and has a hammering effect that can crack or pound a hole through a piston top or break a ring land Figure 2 7 Damage caused by detonation Shindaiwa Inc 1994 JJ O Cc W m m 00 O O lt Q Section 2 Trou bleshooti Ng Troubleshooting IMPORTANT Engine Seizure Most seizures are not covered by the war ranty Whenever warranty is in question determine the cause of failure before disman tling the engine 1 Pressurize the powerhead to 4 6 psi for at least 3 minutes 2 A pressure drop of 2 psi in 3 minutes indicates a leak 3 Locate leaks with a soap solution or General submerge the pressurized powerhead Outright mechanical failures are unusual and in a tank the cause of a seizure can often be identified by examining the spark plug and by viewing the piston through the cylinder ports Shindaiwa p n 72174 99200 When making a diagnosis enter your 0 5 kgf cm on the gauge findings on the Seizure Checklist shown on equals about 7 psi the following page If an air leak is Suspected the assembled engine should be pressure tested for possible leakage from crankcase seals or related gaskets O H O O T 00 Lu l m O am H
31. idle speed Clutch Section Inspect and re tighten holders securely Inspect and replace attachment as required Tighten gearcase securely see the Gearcase and Mainshaft Sections Inspect and replace as necessary See the Gearcase and Mainshaft Sections Shindaiwa Inc 1994 13 Section 2 Trou bleshooti Ng Diagnosing Whenever there is metal to metal contact Engine Seizure between internal moving parts the engine can seize Most engine seizure can be traced to at least one of the following Severe metal galling transfer all around the piston even scoring Lubrication Figure 2 3 E Lack of oil Insufficient or poorly mixed oil ratio Shindaiwa machines are designed to use Shindaiwa Premium 2 cycle Engine Oil at a ratio of 40 1 3 2 ozs U S gallon E Incorrect type oil Generic brand and some outboard motor mixing oils may not provide sufficient lubrication throughout the broad temperature range associated with high performance air cooled engine operation IMPORTANT When Shindaiwa Premium 2 cycle Engine Oil is not available fuel should be mixed with a premium grade 2 cycle mixing oil Specifically designed for use in high performance air cooled 2 cycle engines Figure 2 3 Piston damaged from lack of lubrication O H O O T 00 Lu l m O am H Debris Figure 2 4 E Excessive carbon buildup Carbon buildup can be dislodged from the exhaust Carbon scoring port and jam between piston
32. impulse passage A blocked impulse passage can restrict fuel delivery possibly leading to serious engine damage STEP 3 Install the throttle cap and slide valve assembly on the carburetor The slide valve has a vertical slot that must engage with a locating pin in the slide valve bore STEP 4 Connect fuel and priming discharge lines in the reverse order of disassembly STEP 5 Install the air filter elements in the reverse order of disassembly Install any remaining ducting or covers removed during disassembly CAUTION Screen type elements must be installed with the large mesh black screen on the engine side of the SYOLAYUNEYVD filter Incorrect screen orientation can lead to serious engine damage from ingested debris STEP 6 Fill the fuel tank with fresh 2 cycle fuel Start and warm the engine and adjust idle air mixture as described in the Basic Adjustment section page 25 Using a reliable tachometer adjust low idle engine speed to the specification listed in the Appendix STEP 7 Set the engine throttle lever to the full W O T position and then adjust the carburetor main jet high speed screw until the engine peaks at maximum no load rom As soon as maximum rom has been established enrich unscrew the high Speed adjustment in 1 8 turn increments until the engine begins to stutter slightly STEP 8 Recheck idle speed and perfor mance and adjust as necessary CAUTION
33. in crankcase M M Gently tap crankcase half S into place with a soft faced hammer Figure 8 21 STEP 5 Install crankcase fasteners Coat the crankcase screws with 3 Bond Liquid Screw Lock Shindaiwa stock number 14 01 and torque to the specifica tions shown in the torque chart in the Appendix m Z Q Z mi O I gt Z A O gt 00 m Final Inspection After the crankcase has been torqued to specifications check for proper crankshaft centering by slowly rotating the crankshaft by hand Figure 8 21 Installing crankshaft half S M Any roughness or excessive drag may require centering the crankshaft within the crankcase by sharply tapping each crankshaft end with a soft faced hammer Figure 8 22 E if roughness or drag persist the halves must be disassembled and reinspected Figure 8 22 Crankshaft drag can usually be eliminated by sharply tapping the crankshaft ends with a soft faced hammer Shindaiwa Inc 1994 19 Section 9 Mufflers Description Current Shindaiwa trimmer and brushcutter models feature a unitized sheet metal muffler bolted to the engine cylinder through an oversized gasket The one piece muffler design eliminates annoying vibrations associated with compo nent style mufflers and the oversized gasket also functions as a combination heat shield and cooling baffle Higher capacity mufflers feature a third mounting bolt for additional support All mufflers featu
34. metering cham ber and must be adjusted to recommended specifications See the accompanying table C Inlet Diaphragm Install the inlet diaphragm gasket and cover in the reverse order of disassembly M On T C 25 carburetors make sure the priming air bleed O ring seat is in place and properly oriented before installing the cover The O ring seat is properly installed when its flat side is towards the carburetor casting Making sure the cover is properly oriented and aligned cross tighten the four cover SCrews D Priming Tickler Lever Reinstall the priming lever in the reverse order of disassembly Make sure the lever operates smoothly and if necessary adjust the lever forks to properly retain the overflow purge valve Figure 3 17 NOTE No priming lever adjustment is possible on models T C 25 carburetor with a red plastic priming lever If the priming valve leaks or if the lever contacts the pump cover on these models the priming air bleed O ring seat is damaged and must be replaced Packing surface A__O Metering lever Wyk V Figure 3 16 Measuring the metering lever height Upper surface of metering chamber il JA Dimension A CRB 28 TK METERING LEVER SETTINGS Model F Pie T C 20 T C 25 T C 27 T C 250 C 35 BP 35 B 40 B 45 RC 45 Carburentor Model DPK8W 3B DPV10W DP10W DPV10W 1E DPN1OW 1A DPV11W 1A PC1OWW DPW13 1A DPW12 DPV 1W 1E Lever Heigh
35. ona Snap ring plier with its sharp 90 edge toward the plier handles Install the output side snap ring in the gearcase G m gt JJ 0 gt U m Pp i Ae q Output gear Figure 11 12 Hande fit the output gear into the gearcase Shindaiwa Inc 1994 97 00 Lu lt QO am lt Lu section 11 Gearcases Reassembly Inspection Pinion gear Snap ring and assembly except Models E Slowly rotate the output shaft by hand and seal are tes T C 250 check for excessive bearing drag Shaft om some Modes continued Ci Excessive drag usually can be eliminated Bearing by tapping the input end of the gearcase sharply with a soft faced hammer Figure 11 14 CAUTION a Excessive drag will increase Gearcass Baise operating temperature and can Output Seal Inner sea lead to early gearcase failure If exces bearing gear Snap ring sive drag cannot be eliminated with the above method the gearcase must be disassembled for reinspection Figure 11 13 Gearcase final assembly Lubrication E Fill the gearcase with Shindaiwa lithium based gearcase lube Figure 11 14 then replace the gearcase grease plug and grease collar in the reverse order of disassembly IMPORTANT Do not overfill the gearcase Fill the gearcase only until grease is visible at the output seal CAUTION The grease collar must be remo
36. pistons and bearings and can shorten an engine s performance life significantly Higher octane fuels are designed to burn longer producing a steady and controlled increase in combustion chamber pressures For maximum performance and engine life Shindaiwa engines require a fuel with an octane rating of at least 87 Shindaiwa Inc 1994 IMPORTANT Ethanol will increase fuel octane rating by 2 to 3 points and is often blended with gasoline as an octane enhancer or booster Volatility For easy starting and maximum engine performance gasoline must remain in a liquid state only until it enters the carburetor venturi Gasoline evaporates more rapidly ina warm climate than in a cool climate and high volatile gasoline will cause performance problems if it vaporizes in the engine s fuel lines or carburetor The opposite is true in cool weather A low volatile fuel can puddle in the combustion chamber and cause an engine to be hard to Start IMPORTANT Gasoline is blended seasonally Non seasonal gasoline can cause hard starting due to either vapor lock or puddling Always purchase gasoline from a high volume dealer Alcohol and Water Condensation can produce water droplets on the inner walls of fuel tanks and other storage containers These droplets can be readily absorbed by any alcohol in the fuel If the alcohol involved has been blended with gasoline this new alcohol water mixture is prone to phase s
37. secondary Figure 5 16 Analyzer and simulator Imrie shown Ignition Systems Section 9 STEP 2 Test the spark plug firing voltage Groundio Insert in spark between the coil high tension lead and engine plug lead the spark plug terminal Figure 5 18 This test demonstrates the voltage required to fire the plug The difference between required voltage and available voltage is referred to as ignition reserve voltage E f required voltage at cranking speed is Crank p engine more than 50 of available voltage regap N briskly or replace the spark plug with a Champion CJ8 spark plug or equivalent set to 024 0 6mm and retest IMPORTANT Available voltage must always be greater than required firing voltage or the plug will misfire and fail under load As a rule of thumb required firing voltage generally increases about 1 kV for every 001 of additional plug gap A high firing voltage indicates unusually Figure 5 17 Available voltage at cranking speed should be at least 18 kV or higher high resistance within the spark plug and Connect to increases the possibility of ignition failure spark plug een aak under load Ground to p engine plug lead STEP 3 Measure primary coil voltage Disconnect the ignition stop switch and use the analyzer to measure voltage between the primary windings and ground Primary coil voltage at cranking speed should be approximately 120 volts or more
38. the engine cooling system Installation or use of a damaged modified or otherwise non standard muffler gasket can lead to engine failure through overheating U am Lu TH TH STEP 3 Coat the muffler bolt threads with Three Bond 13 60 Liquid Screw Lock STEP 4 Hand tighten the muffler to the cylinder E For mufflers with two attachment bolts final torque both bolts to the specifications listed in the Appendix E For mufflers using a third support bolt coat the support bolt s threads with 13 60 Liquid Screw Lock then install and se curely tighten the support bolt before torquing the two muffler bolts CAUTION A A loose or missing muffler support bolt can allow the muffler to loosen during operation elongating the bolt threads and possibly fracturing the cylinder flanges Always make sure all muffler bolts are correctly installed 82 Shindaiwa Inc 1994 Mufflers Section 9 Spark Arrestor Assemble the spark arrestor in the reverse order of dissassembly ca Replace all gaskets with new Shindaiwa Typical gaskets of the appropriate part number and then securely tighten the arrestor cap retain ing screw s CAUTION Operating a trimmer or brushcut ter with a missing or damaged Spark arrestor is a fire hazard and may also be illegal in your area Consult USFS and state local authorities for applicable safety notices and regulations EBEE Shindaiwa Inc
39. valves A check valve can be tested by covering the valve with one end of a clean primer hose and then blowing pulling air through the hose to confirm valve operation Tip on replacing check valves Walbro p n 84 555 STEP 1 Screw a small sheet metal screw into the hole in the center of the check valve STEP 2 Grasp the sheet metal screw with pliers then extract and discard the defec tive check valve STEP 3 Install a new valve and press it in to the same depth or Use Walbro tool kit p n 500 500 and follow the procedures outlined with the kit Shindaiwa Inc 1994 43 U an Lu H lt H 00 O O Lu section 4 Recoil Starters General All Shindaiwa trimmers and brushcutters use a manual starting system that permits an operator to generate engine cranking speed by pulling on a rope wound around a pulley or reel When the operator pulls rapidly on the starter rope a ratchet mechanism temporarily connects the moving starter pulley to a hub mounted on the engine s crankshaft Extend ing the rope also winds a clock type spring contained in the starter housing When the rope has been pulled to the end of its travel energy stored in this recoil spring can be used to automatically rewind the starter rope around the pulley IMPORTANT Most recoil starter failures are caused by abusive engine cranking procedure and can usually be traced to a hard starting engine When you encounter a starter wi
40. 100 C with a heat gun Then remove the drive pinion and bearing seat from the gearcase by tapping the input end of the gearcase sharply against a flat wooden surface Figure 11 19 IMPORTANT steel faced or other hardened striking tools should never be used in gearcase disassembly Oil Seal and Snap Ring Figure 11 19 Removing the 250 pinion gear WE Carefully pry the oil seal from the output side of the gearcase using a pick or straight bladed screwdriver E Remove the snap ring from the output cutting attachment end of the gearcase Turn counter using Snap ring pliers Gearcase clockwise to remove Output shaft Output Shaft and Bearing Removal STEP 1 Thread the puller bolt completely into the puller body STEP 2 Thread the shaft puller bolt into the gearcase output shaft turn counter clockwise until the puller body bottoms against the gearcase Figure 11 20 STEP 3 Continue turning the shaft bolt until the output shaft and bearing assembly are Figure 11 20 Removing the 250 output shaft completely free from the gearcase housing Puller NOTE If shaft removal is difficult use a heat gun to ore heat the gearcase to approximately 212 F 100 C Inner Bearing Removal E Pre heat the gearcase with a heat gun to 7 approximately 212 F 100 C Remove the inner bearing by tapping the gearcase sharply against a flat wooden surface Figure 11 21 00 Lu 00 lt QO am lt Lu
41. 1994 B3 section 10 Mainshafts and Outer Tubes Straight Shaft All Shindaiwa straight shaft trimmers and Trimmers brushcutters feature one piece high carbon steel mainshatts Shafts are splined at both ends to minimize wear and vibration and are usually supported by either four or five pre lubricated bushings housed in an extruded aluminum outer tube Shaft bushings are isolated from the outer tube by rubber anti vibration A V mounts On most models torsion control is pro vided by either a hollowed or relieved mainshatft Outer tube dimensions vary between models refer to Specifications in the Appen dix but all tubes are manufactured from aircraft aluminum and are mandrel drawn This manufacturing process produces a seamless outer tube with consistent toler ances superior bend resistance and a nearly flawless finish 00 Lu oO 00 H LL lt T 00 lt 84 Shindaiwa Inc 1994 Mainshafts and Outer Tubes section 10 Disassembly Mainshaft Removal Where used a relieved mainshaft must always be STEP 1 Remove either the powerhead or installed with its relieved end gearcase from the shaft tube closest to the powerhead STEP 2 Slide the mainshaft from the outer tube assembly IMPORTANT Note mainshaft orientation during disassem bly A hollow mainshaft may be installed end for end but a relieved narrowed mainshaft must be installed with its narrowed torsional relief toward the en
42. 210 Driver 22015 96310 Driver 22015 96410 Driver Walbro Pressure Test Gauge Walbro p n 57 11 Shindaiwa p n 99909 93 Walbro Carburetor Service Kit Walbro p n 500 500 E Walbro Metering Lever Height Gauge Walbro p n 500 13 E Cylinder Block Pressure Test Kit includes block off plates and gauge Shindaiwa p n 72174 99200 Miscellaneous Tools Shindaiwa Inc 1994 1 15 Notes 1 16 Shindaiwa Inc 1994 Shindaiwa Incorporated 11975 SW Herman Road P O Box 1090 Tualatin OR 97062 Phone 503 692 3070 FAX 503 692 6696 1994 Shindaiwa Inc Form No 60506 Printed in U S A Shindaiwa is a registered trademark of Shindaiwa Inc Printed on recycled paper Reprinted 5 00 1M
43. 50 requires removing the output driven shaft and gear together as a single component E Flexible cable service and repair proce dures are similar to the procedures for Shindaiwa flex shaft trimmers Refer to section 10 CAUTION Flexible cables for Shindaiwa lawn edgers must be cleaned and re lubricated at least every 50 hours of operation or when the unit is returned to service after extended storage Inadequate cable lubrication can cause rapid wear of the flexible cable and the liner resulting in increased vibration and greatly reduced service life Shindaiwa Inc 1994 1 03 v O H lt O LI A gt lt m LLI A A lt section 13 Appendix Specifications See it che ENGINE Displacement cc cu in Bore stroke Horsepower RPM maximum hp Maximum no load RPM Weight Ib kg Power weight hp Ib Specific output cc per hp Idle RPM 100 Clutch engagmnt rpm 250 Crankshaft Crankshaft bearings Conrod Conrod bearing large end Conrod thrust control Piston Rings Cylinder Crankcase pressure test FUEL SYSTEM Carburetor Model Primer Air Purge Adjustment H Adjustment L Mounting method Filtration Fuel tank location Tank Mounting System Number of Elements Tank Capacity metric ounces Fuel Vent Vent location Recommended fuel Fuel oil ratio CLUTCH Material Number of Shoes Number of Springs RECOIL Housing material Attachmen
44. 994 Ignition Systems Section 9 Refer to Figure 5 2 The high voltage surge causes the TCI to Timing at electronically switch off and interrupt the 6 000 rpm flow of current through the primary coil This sudden loss of current causes the Timing at magnetic field to collapse rapidly around both Timing at cranking coils 10 000 rpm The moving magnetic field now causes the magneto s primary and secondary coils to function together as a powerful transformer Na eee and primary coil voltages are multiplied by off one hundred times or more within the second ary windings Voltage Increases gt gt secondary coil voltage continues to rise only until it reaches whatever voltage is required to bridge the spark plug gap and IGN 22 complete the circuit to ground pees 4 Ignition shutdown is accomplished by _ Timing Advances physically grounding the magneto s primary coll with a mechanical on off switch The Figure 5 3 Spark timing is automatically controlled by switch temporarily overrides the TCI unit and echanges in the shape of the primary coil s voltage any remaining system voltages are then too wave form which in turn is determined by flywheel low to bridge the spark plug gap rpm Collapsing magnetic field No current flow High Secondary voltage coil Primary ca 44 Voltage jumps the gap as current completes the Circuit SINALSAS NOILINDSI Figure 5 2 Rising primary v
45. Before storing any trimmer or brushcutter always drain the fuel tank and then operate the engine until all remaining fuel is drained from the carburetor and fuel lines 100 100 90 90 80 80 70 70 60 60 50 50 40 40 30 30 20 20 FUL 13 10 alcohol 10 Water No alcohol 10 water Recommendations When using oxygenated fuels E Never use any fuel containing more than 10 alcohol by volume See the sidebar Shaker Test When an oxygenated fuel must be used choose an ether based oxygenate over one containing alcohol To minimize the risk of lean seizure when using oxygenated fuels Shindaiwa recom mends enriching carburetor fuel settings at least 5 Use only fuels with an octane rating of 87 or higher and purchase only seasonally blended fuels from a high volume dealer Never store a trimmer or brushcutter with fuel remaining in the carburetor or fuel lines Pre treat all stored fuels with an appropriate fuel stabilizer such as StaBil Always use Shindaiwa Premium 2 Cycle Engine Oil mixed at a fuel oil ratio of 40 1 3 2 ozs U S gallon If Shindaiwa brand engine oil is not available fuel should be mixed with a premium grade 2 cycle oil specifically designed for air cooled en gines IMPORTANT Under certain conditions oxygenated fuel can cause an engine to operate lean If a two cycle engine must be operated with oxygen ated fuel the engine s high speed adju
46. EP 1 Place the reel into the recoil hous ing Replace the pawl actuating mecha nism in the reverse order of disassembly Install and tighten the center screw securely For starter models with a metal recoil housing apply LocTite or similar adhe sive when making this installation NOTE Units T F 18 and T C LE 230 are assembled with a wave washer and retainer Figure 4 1 When servicing these units make sure these two components are oriented correctly on the recoil housing center post STEP 2 While holding the starter rope in the reel notch wind the reel 2 to 3 turns M Clockwise rotation for F 20 WH All other units wind in a counter clockwise direction Shindaiwa Inc 1994 Grasp the spring firmly before removing the outer retaining wire Newer T C 25 cassette springs can be removed from the cassette for use in older units but they must first be rewound inside a jar lid or similar appliance see the text Retaining wire Figure 4 6 Grasping the recoil spring Use a stopper Knot to install the cord in the reel E oe Figure 4 7 Stopper knot 6 to 8 inches of exposed cord Figure 4 8 Installing the reel Recoil Starters section 4 Replacing the STEP 1 With 6 to 8 inches of starter cord still Handle protruding from the reel notch wind the general reel 2 to 3 turns counter clockwise clock wise on F 20 See Figure 4 8 STEP 2 While holding the reel in place with yo
47. Exhaust Expanding gasses continue to force the piston downward As the piston exposes the exhaust port most of the spent combustion gasses are expelled through the port and out the muffler 6 Transfer The piston s downward movement covers the intake port and simultaneously opens the transfer port That allows the compressed fuel air mixture from Step 1 to enter the cylinder As the fresh fuel air mixture enters the cylinder it also helos push or scavenge remaining exhaust gasses out through the exhaust port OSNILOOHSATENOdL Figure 2 2 The burning mixture expands forcing the piston down and rotating the crankshaft Continued piston movement compresses the fresh mixture in the crankcase As the piston exposes the transfer port crankcase pressure forces fresh mixture into the combustion chamber and helps push the remaining exhaust gasses through the exhaust port Shindaiwa Inc 1994 9 Section 2 Trou bleshooti ng Factors That All Shindaiwa products are powered by high 1 Lubrication Affect Durability performance engines that produce the most Proper lubrication is essential for reducing horsepower from the lightest possible design friction between an engine s moving parts Two factors are critical to the service lite By reducing friction lubrication also helps and durability of any high performance reduce the heat developed during engine SIGUG operation Since a 2 cycle engine doesn t have a reservoir of oil in i
48. YYI U am O H Lu CC aa lt O Section 3 TK Carbu retors Inspecting TK Carburetors continued H Choke Assembly Make sure the choke lever and other choke components are not loose damaged or missing Service parts for choke assemblies used on most TK equipped Shindaiwa products are available as individual part numbers and are listed on the following CAUTION If choke components must be replaced always stake the choke nut as described below An improperly staked choke nut could work loose and enter the engine causing major engine failure Chart HT 20 and T 20 T C 25 T C 27 B 45 RC 45 CHOKE The original choke PLATE plate of HT 20 and shown actual T 20 units can be size removed for reuse by ae carefully grinding off WHEN INSTALUING Me meee DING EnOKE KEEP BEND OF TAB shaft rivet with a small TOWARD CARB die grinder or Dremel BODY tool 11185711054 1009 2611 30 11272611200 11092611008 CHOKE An exact replacement LEVER choke lever for HT 20 Ga shown actual and T 20 units is not size available at this time Part No 11112521103 Lever will work but the handle tabs are reversed from the original position 11112521103 CHOKE SHAFT SPRING WASHER AND NUT same parts fit all models NOTE P N 11052312002 Choke Shaft fits all TK carburetor models listed and must be installed with its threaded end toward the air filter Some choke plates may need to be filed sl
49. a heat gun as shown in Figure 8 10 Bearing STEP 1 Drive the bearing into the crankcase using the appropriate bearing driver and a dead blow mallet until the bearing con tacts the base of the bearing bore Figure 8 12 STEP 2 Spin the installed bearing to test for roughness or excessive drag Replace if necessary NOTE Avoid excessive hammering Avoid using a Bearing bore heavy steel hammer when driving bearings Figure 8 12 Installing a bearing with a driver Doing so can cause bearing rebound result ing In an improperly seated bearing Drive the bearing only until it contacts the base of the bearing bore Do not use exces sive force If available use an arbor press to provide a much improved feel during bearing installation Figure 8 13 m Z Q Z mi O D gt Z A O gt 00 m Bearing Crankcase Seal Installation CAUTION half Seal integrity is vital to engine performance and longevity Always replace both crankcase seals during major engine overhaul Always Figure 8 13 Installing bearings with an arbor press pressure test the assembled engine after replacing seals and bearings Refer to Section 2 STEP 1 Apply grease Prior to installing either seal apply a small amount of grease both around and behind the seal s neoprene lip Figure 8 14 A seal with a rubberized outer coating requires no further attention but an un coated metal seal O D should receive a thin coating of Th
50. ace both piston rings during teardown E if piston rings are to be reused carefully inspect them Inspect ring edges for wear or rounding and check ring ends for signs of cracking or chipping STEP 2 Measure piston ring thickness and width with a micrometer and use a thick ness gauge to measure piston ring end gap with the individual rings installed about halfway into the cylinder bore Figure 7 10 Dimensions should be within the toler ances listed in the Appendix IMPORTANT If there is ever a doubt about the condition of either piston ring replace both rings as a set P N 72182 96300 Figure 7 8 Removing a piston pin with a driver Piston rings End gap Ring grooves Locating pins CYL 13 Figure 7 9 Piston ring end gaps must be spaced over the appropriate locating pins in the piston grooves Piston ring Measure end gap with a thickness gauge Figure 7 10 Measuring ring end gap Shindaiwa Inc 1994 6 lt lt U m JJ V x O Z 00 section Cylinders and Pistons Inspection Thrust Washers continued WH f either thrust washer shows obvious signs of wear or discoloration from high tempera ture operation replace both washers as a Set 00 O 2 A 00 CC Lu m m gt O Small End Pin Bearing and Piston Pin Inspect the bearing and pin for visible signs of wear Also inspect for damage such as chipping fractures gall
51. al grounding For an engine to run the stop switch must show an open circuit no meter movement when in the run position STEP 4 Test all ground connections Individually loosen and tighten the appro priate component mounting screws or fastenings then retest for spark as in Step 2 E f a steady blue spark now appears with each rotation of the flywheel remove and clean all metal to metal grounding connec tions Actual current flow is very low within a TCI system and can easily be blocked by small accumulations of dirt or corrosion Shindaiwa Inc 1994 Adjustable gaptester _ af AD Unplug the stop switch lead typical Figure 5 9 Disconnecting the stop switch Ground to engine Switch lead MULTIMETER pc ACV KO OFF CHECK CON Figure 5 10 Testing the stop switch with an ohmmeter Ignition Systems Section 9 STEP 5 Check magneto air gap Figure 5 11 Gauge p n ier Make sure the magneto air gap is setto the 20000 96210 f specifications listed in tune up chart in the Appendix IO O O O O CAUTION O Electronic components can be easily damaged by operating the unit at excessive temperatures When specified in the IPL protective insulators Figure 5 11 Measuring Figure 5 12 are essential to ignition peg ne Gee component life and must NEVER be removed Insulators STEP 6 Test ignition unit two piece ignition
52. al of T F 18 T C 230 r Friction Recoil Starters section 4 Disassembling the Recoil WARNING Wear eye and face protection when servicing recoil starters Coiled starter springs contain stored energy and may cause injury if suddenly released Remove the 3 or 4 fasteners that secure the recoil starter housing to the engine crankcase Tie a slip knot to prevent the starter cord Release Spring Tension Pull 8 to 10 inches of starter cord from the recoil housing and tie a slip knot Figure 4 2 from where the cord enters the housing secs E if the cord is to be replaced housing Cut the cord where it enters the handle Untie the slip knot in the starter cord and allow the cord to rewind slowly back into the housing E If the cord is to be reused Use a needle nose pliers to withdraw the Knot from the operator side of the starter handle Untie the knot then slide the handle from the cord Untie the temporary Knot at the recoil housing then allow the cord to rewind slowly back into the housing Figure 4 2 Slip knot Remove the Reel Retaining Screw Use a screwdriver to remove the recoil reel retaining screw Turn counter clockwise all models NOTE The reel retaining screw is precoated with a screw locking agent to prevent it from loosen ing during operation To ease its removal from a cast metal recoil housing first heat the housing threads to approximately 212F 100C with a hea
53. an cover and ducting Shindaiwa Inc 1994 63 O a Cc O T 7 lt e m m 00 O 2 A 00 CC Lu m m gt O section Cylinders and Pistons Construction Cylinder Removal Inspection 64 All Shindaiwa trimmer and brushcutter engines combine a two ring piston running in a hard chrome plated cylinder bore The second piston ring permits Shindaiwa engines to develop more power through better sealing while providing better piston support for longer product life The hard chrome plated cylinder walls are electronically etched for oil retention produc ing an extremely durable and long lived bore All Shindaiwa trimmers and brushcutters use a thrust control system at the small end of the conrod for better lubrication at high RPM and less wear to thrust surfaces Figure 7 1 STEP 1 Disconnect the high tension lead from the spark plug and remove the fan cover housing varies by model STEP 2 Disconnect the throttle cable and fuel lines Remove the muffler as described in Section 9 STEP 3 Remove the cylinder base screws Figure 7 2 then carefully pull the cylinder from the piston and crankcase assembly Carefully examine the cylinder bore for any signs of scuffing scoring aluminum deposits or visible wear CAUTION Do not rotate the cylinder on the piston Rotating the cylinder may cause piston ring ends to catch and possibly break in the cylinder
54. and cylinder produces soft edged grooves on the E Operating the engine with a faulty or exhaust side of the missing air filter Dirt water or other piston Piston rings debris enters the crankcase and cylinder are still free in the grooves scoring the piston and cylinder and causing rapid component wear Ingested debris produces a sand blasted appearance or a dull grey surface on the intake side of the piston away from the arrow The piston Skirt is worn thin at the base Ring lands are worn Ingested water or snow leaves a shiny polished area on the intake side away from the arrow Figure 2 4 Operating with debris in the cylinder 14 Shindaiwa Inc 1994 Troubleshooting section 2 Overheating Figure 2 5 E Operating an engine with clogged or damaged cooling fins or with missing cooling system components can cause internal moving parts to expand beyond normal rates and dimensions and allow metal to metal contact IMPORTANT Overheat damage is most often caused by forcing the engine to turn with excessive trimmer line dull or oversized attachments or by failing to select the proper size and capac ity trimmer obrushcutter for the application E Preignition Figure 2 6 from incorrect Spark plug or carbon buildup may result from lean carburetor setting as well E Incorrect or lean fuel air ratio Figure 2 6 Operating an engine at an oxygen rich carburetor setting raises combust
55. bles correct orientation of the piston ring end gaps within the cylinder and must always point toward the exhaust side of the cylinder Improper piston installation can allow the piston rings to hook and fracture in the cylinder porting resulting in major engine damage Circlip Removal Use a tapered pick to remove each circlip Figure 7 6 WARNING Wear eye protection when working with circlios Circlips are under spring tension and can be unpredictable during removal CAUTION Never attempt to straighten or reuse acirclip The circlip should lay flat and form a perfect circle Always install new circlipos during reassembly Never attempt to substitute circlips from another engine make or model Piston Pin Removal Piston pins are press fit Avoid damaging or distorting the piston or crankshaft assembly during removal Use one of two methods for removing a piston pin Piston Pin Removal Method 1 While supporting the piston with your hand Figure 7 7 drive the pin out with the appro priate guide pin driver tool and a dead blow hammer Remove the thrust washers and bearing as the piston is removed CAUTION Never attempt to remove a piston pin from an unsupported piston Failure to properly support a piston during pin removal can cause damage to the piston as well as the crankshaft assembly 66 Shindaiwa Inc 1994 Before removing the piston all models note the orientation of the arrow
56. bleshooting Troubleshooting the primer and air purge the WZ systems usually requires no more than Carburetor cleaning and servicing the check valves and bulb Before troubleshooting inspect and clean the fuel filter as required Inspect and replace any plugged or deteriorated fuel lines as well and replace any primer purge bulb showing evidence of cracking leaking or hardening PROBLEM The primer will not depress 1 Inspect the fuel return line for kinks or plugging Repair or replace as required 2 Ihe discharge valve may be plugged Clean and retest as required PROBLEM The primer remains collapsed 1 The inlet valve may be stuck in the closed position Clean and retest as required 2 There may be a restriction in the fuel line or filter Repair as required PROBLEM The primer fills with air 1 There may be a leak in the fuel line Pressure test the line and replace as required 2 Ihe discharge check valve may be stuck open Clean and retest as required 3 The nozzle check valve may be stuck open Clean and retest as required 4 Butterfly carburetors Close both needles and operate the air purge If the bulb fills with fuel the check valve is stuck open Clean the valve and retest as required IMPORTANT Any defect that prevents the carburetor from getting fuel to the engine will also prevent the air purge or primer from working gt JJ W Cc JJ m O JJ 00 Tip on testing check
57. cast into the piston Arrow Figure 7 5 The cast in arrow must always point toward the exhaust muffler side of the cylinder NY Figure 7 6 Using a tapered pick to remove a circlip Support the piston Figure 7 7 Removing the piston pin with a driver Inspection Cylinders and Pistons section 7 Piston Pin Removal Method 2 Using pin removal tool p n 72182 96300 and the appropriate push pin press the pin from the piston Figure 7 8 Remove the thrust washers and bearing as the pin is removed IMPORTANT Avoid breaking the piston ring while using the pin removal tool When installing the tool on the piston make sure the piston ring end gaps are properly spaced over their appropri ate locating pins on the piston Figure 7 9 Piston Inspect the piston for wear scuffing scoring operation with a loose piston pin cracking or other damage lt Be especially alert for damage caused by ingested water or debris Carefully inspect for any damage or wear to the piston ring grooves or lands Whenever a piston s overall condition is questionable inspect and compare key wear areas with the specifications and tolerances listed in the Appendix Rings STEP 1 Using finger pressure alone spread each piston ring only enough to permit the ring to just clear the piston crown E Except for low time engines or engines disassembled for reasons other than internal component failure always repl
58. correct mixture Shindaiwa Premium 2 cycle Engine Oil and gasoline 40 1 ratio other brands 25 1 ratio a H O O E 00 Lu l aa O am H Fan fan cover cylinder fins dirty or damaged Clean repair or replace as necessary Carbon deposits on Decarbonize Refer to the Piston and the piston Cylinder Section meoo Clogged air filter Service the filter an oua Loose or damaged Tighten or replace all soeeds spark plug Do e Air leakage or debris Repair or replace filter and or fuel line Refer in the fuel system to the Carburetor Section pressure test TA Water in the fuel Replace the fuel unburned fuel ate SANE Piston seizure Refer to the Cylinder and Piston Section Faulty carburetor and or Refer to the Carburetor Section diaphragm Overheating condition Refer to the Lubricants Section fuel mixture The engine Nea knocks while Carb Section carb settings spark plug Improper fuel Check fuel octane rating check for running presence of alcohol in the fuel Refer to the Fuel and Oil Section of the Appendix Refuel as necessary Carbon deposits in the Decarbonize refer to the Piston and combustion chamber Cylinder Section 12 Shindaiwa Inc 1994 Trou bleshooting Section 2 Troubleshooting Guide Symptom Poor acceleration Engine stops abruptly Engine difficult to shut off Cutting attachment rotates at engine idle
59. d bearing bores The gearcase assembly is also machine bored to accept the trimmer shaft tube and is secured to the shaft tube by a clamp screw and most units a locating bolt The gearcase drive gear is internally splined to accept the trimmer mainshaft The output shaft features both external splines and internal threads to accommodate a wide variety of cutting attachments Gear lubricant is lithium based grease and lubricant replacement is accomplished by removing a shaft collar and injecting fresh grease through a threaded hole in the side of the gearcase IMPORTANT Special tools required for gearcase service are listed in the Appendix STEP 1 Remove the cutting attachment and blade holders Use slip joint pliers to withdraw the shaft collar Figure 11 2 STEP 2 Loosen the clamp screw remove the locating screw and gearcase filler plug and slide the gearcase assembly from the shaft tube CAUTION The mainshaft is splined at both ends and can easily be damaged if allowed to fall from the shaft tube STEP 3 Use snap ring pliers such as Snap On PR 23A or equivalent to remove the snap ring from the output cutting attachment end of the gearcase Figure 11 3 WARNING Always wear safety glasses when working with snap rings Shindaiwa Inc 1994 Gearcase housing Snap ring Pinion bearings Drive Gear Seal Output shaft d i OU NG
60. d of l this Section 9 NOTE Barrel valve Walbro p n 57 11 pressure tester or equiva J lent is essential for proper service of Walbro carburetors In addition the Walbro tool kit p n 500 500 can simplify many Walbro service and repair procedures Body A Carburetor Removal WYL shown When servicing other models refer to appropriate IPL Fuel pump diaphragms and gaskets STEP 1 Open the air filter cover to expose the two carburetor retaining screws STEP 2 Remove the carburetor retaining screws and remove the air filter assembly ois Filter screen STEP 3 Using finger pressure only slide the Tas ae overflow tube retainer past the barb on the overflow outlet fitting STEP 4 Gently pull both the fuel line and assembly overflow tube from the carburetor body gt 1 mil SYyoO1JYNGYYI Metering body Metering valve STEP 5 Disconnect the throttle control wire from the throttle lever assembly then Metering remove the carburetor from the power diaphragm head and cover assembly B Air Purge Primer Bulb STEP 1 Unscrew the four metering cover retaining screws and then remove the cover primer pump bulb Figure 3 21 and Check valve the plastic purge body assembly Purge assembly STEP 2 Using the flat tip of a small screw driver carefully remove the check valve KI ee ee CAUTION Never use scrapers or other metal tools to separate carbure tor covers gaskets or diaphra
61. driver turn the inner idle needle counter clockwise to remove STEP 3 Remove the inner idle needle and spring Cleaning Clean all internal passages with compressed air If a commercial carburetor cleaner is used remove it and all residue immediately follow ing its use with conventional solvent CAUTION Commercial carburetor cleaners may remove protective internal coatings and casting fillers Use these cleaners only when absolutely necessary and for brief periods only 36 Shindaiwa Inc 1994 Walbro Carburetors section 3 Inspecting A General Walbro Outright failure of any carburetor is unusual Carburetors Most carburetor problems are caused by debris or other fuel related problems M During disassembly closely examine internal jets and passageways for signs of accumulated dirt or debris E Diaphragms and other non metallic components can be damaged by exposure to stale fuel or by fuels with an unusually high alcohol content E Be alert for stripped threads on fasteners or adjustment screws as well as any hidden physical damage B Throttle body and Nozzle Inspect the throttle body casting for damage such as stripped threads cracks distortion damaged nozzle etc f the throttle casting is worn or dam aged beyond serviceability the entire carburetor must be replaced gt JJ W Cc JJ m O JJ 00 C Barrel Valve M Rotate the throttle lever by hand The barrel valve shou
62. e Reinstall powerhead and or gearcase in the reverse order of removal 00 Lu oO U H LL lt zE 00 lt CAUTION Torsion relieved mainshafts must be installed with the relieved narrowed section toward the powerhead end of the shaft tube Reversed installa tion will cause the mainshaft to vibrate leading to accelerated spline wear If subjected to high shock loads an improp erly oriented shaft may fail during use 88 Shindaiwa Inc 1994 Mainshafts and Outer Tubes section 10 Troubleshooting Vibration Complaints Trimmer obrushcutter vibration can be difficult to trace by touch alone Vibrations generated by a faulty powerhead or unbalanced acces sory can travel along the entire length of the machine The dynamic range roms where a vibration is reported will often reveal its actual source E Vibration at low rom only is likely from normal clutch engagement and can often be cured by educating the user Refer also to Section 6 Clutch Orientation E Vibration within a narrow rom band during cutting is often caused by an out of balance attachment M Vibration above clutch engagement speeds and throughout the entire rom range often indicates a bent shaft and or damaged shaft and bushings When tracking vibrations by elimination a good rule of thumb is to work inward from each end of the machine see Vibration Troubleshooting at the end of this Section Flexible
63. e Jet T C LE 230 2214 2214 2214 n a n a 11 8 n a n a n a n a n a n a n a n a Captive nut Insulator Block F 18 I 18 F 20 F 21 I 20 Insulator Block T C LE 230 Boot and Insulator Block Oiled Foam Element all models Under Engine all models Cushion all models 4 4 2 4 4 500cc 16 8 500cc 16 8 400cc 11 8 510cc 17 2 F21 T20 510cc 17 2 6 liters 20 T C LE 230 and T C LE 250 Duckbill Duckbill Screw Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Duckbill Duckbil Remote Remote Tank Remote Remote Remote Remote Remote Remote Remote Remote Unleaded Regular all models 40 1 all models Failure to use manufacturer s recommended oil ratios could void manufacturer s warranty See warranty policy for details Bonded Bonded Bonded Bonded Bonded Bonded Organic 1 C LE 230 and T C LE 250 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Nylon Nylon Diecast Nylon Nylon Glass filled Nylon T C LE 230 and T C LE 250 4 4 4 4 4 4 4 4 4 4 4 3 3 3 3 3 3 3 3 0 3 0 3 0 199 99 845 845 845 199 fod 155 826 826 826 104 Shindaiwa Inc 1994 Appendix Specifications section 13 IGNITION Ignition type Components Minimum output voltage Coil flywheel air gap Ignition timing Spark Plug Recommended Spark Plug Alternative NGK Spark Plug gap MUFFLER Muffler type Attachment points ANTI VIBRATION Engine lower unit Front Handlebar Soft rear handgrip Spring rubber on harness LOWER UNIT Drive Type Gearcase ratio Gearcase Pain
64. e PUCP e ak aaa anga ag a a aa E a Ag aa neds naela bagan A ak Oil Mix Ratio Brand of Mix Oil 6 Was Oil Mixed in Fuel blotter test c cceccescccccessesesesssseseeseensenreereees No 1 Yes fy 7 Was Alcohol Present Shaker test ccccccccseceeseeeeeeeeeseeeeseeeeseeeees No Yes Percent 8 Carburetor Adjustment number Of turns ccccccseeeeeeeeeeeseeeeenees High Low 9 Spark Plug COI OVA CONG Ea cresies awa Aka TENAN aaa Na Wada WANA NADA AKA NGANA aaa a Wa ag a Ka KAEN Brown Tan White Fouled 10 Plug Manufacturer sasa eaa nenen enaa anana nana nnnnnnnananaea i OO GAL RANGE saananipun ana nang aaa agi d iga aaa kai angi kaanan aoo a a o 11 Muner Quiller Cs 6 aaa apana gak BA Ta Aga ag A BAN Pa EA Yaa BAN aga a AE ea eee ajara aa eee Black White 12 Muffler Inside a esteueonstieinnnsnierin asian ta anncensat lt t cnatinehanuetanisctiate teadinctanbenadens Oily Dry 13 812 6G oc 0 eee ene ee nee een eee eee an Ki No Carbon Carbon Recently Cleaned 14 Cylinder Exhaust Port raed tieuctannn spuensaeegnnes sintina anana anana asic teacsidyretentucadiadunteueeanetanne Clean Heavy Carbon 15 Piston Condition view through ports ERAUS sts NAN NA ANNA AA TG eos E E NENG NE NATA E TA ENT TAN Clean Scuffed TING aaa naen na Aan eaaa a ce a aaa ia aa DE a en E a ada nol a Ba aaa a aa sees Clean Scuffed 16 Air Filter Clean Dirty _ Torn _ 17
65. ements Surrounded by boxes and pre ceded by the triangular Attention Symbol WARNING A statement preceded by the word WARNING contains information that should be acted upon to prevent serious bodily injury CAUTION A statement preceded by the word CAUTION contains information that should be acted upon to avoid damaging your machine 2 Shindaiwa Inc 1994 Additional attention statements that are not preceded by the Attention Symbol are IMPORTANT A statement preceded by IMPORTANT is one that possesses special significance NOTE A statement preceded by NOTE contains information that is handy to know and may make your job easier A statement preceded by a pointing finger is a tip suggestion or other trick of the trade that just might ease your task Model Designation and Indentification section 1 SHINDAIWA ENGINE Located on the engine Curvecd shaft Typical identification Grass Trimmers placard locations Mops xxxx xX R XXXXXXX ai IAAON ACC 20 SP Ex Typical nameplate location F 18 Grass Trimmer E ar aN a ee ji A f LANG 1h B p Ca F 230 Grass Trimmer F 20 Grass Trimmer F 21 Grass Trimmer Shindaiwa Inc 1994 3 section 1 Model Designation and Indentification Straight shaft Grass Trimmers 1 16 Grass Trimmer 4 Shindaiwa Inc 1994 Model Designation and Indentifica
66. eparate and form a separate and highly corrosive layer at the bottom of the fuel tank If this layer is drawn in through an engine s fuel filter the engine will burn a highly oxygen ated fuel mixture with little or no lubricating oil IMPORTANT Alcohol blended with gasoline can absorb water and may phase separate to form a water alcohol mixture that can shorten engine life dramatically Appendix Fuel and Ol Section 13 100 90 80 70 60 50 40 30 20 10 Water Shaker Test Storage Gasoline is a complex blend of many different compounds some of which may degrade during storage Old or stale gasoline in an engine s fuel system can attack or deteriorate fuel lines carburetor diaphragms and related fuel system components If a trimmer or brushcutter must be stored longer than 30 days Shindaiwa recommends either E all unused fuel be removed from the fuel system by draining the fuel tank then running the unit until it stops from fuel Starvation or pre treating all fuel supplies with a fuel stabilizer such as StaBil follow the manufacturer s directions IMPORTANT Gasoline octane and volatility can degrade rapidly during storage If gasoline is to be stored for a period longer than 30 days shindaiwa recommends the use of a high quality fuel stabilizer such as StaBil or similar product IMPORTANT some gasoline compounds may deteriorate certain fuel system components
67. equivalent to remove the internal snap ring from the input driveshaft end of the gearcase Figure 11 6 STEP 2 Thread the appropriate long puller bolt into the base of the pinion puller tool STEP 3 Assemble the puller to the gearcase and pinion Figure 11 7 then rotate the puller bolt to remove the pinion and bearing assembly Gearcases section 11 Figure 11 4 Use a pick or small screwdriver to pry out the output seal from the gearcase Puller To remove Figure 11 5 Removing the output shaft Input end of gearcase Snap ring Figure 11 6 Remove the snap ring from the input end of the gearcase Puller Pinion gear assembly Rotate to remove Puller nut Figure 11 7 Removing the pinion and bearing assembly GRC 17 Shindaiwa Inc 1994 95 Q m gt JJ 0 gt 0 m Pp section 11 Gearcases Disassembly Inner Bearing Removal except Models WH Use a heat gun to pre heat the gearcase to T C 250 approximately 212 F 100 C and then 7 continued remove the inner bearing by tapping the gearcase output end sharply against a flat wooden surface Figure 11 8 GRC 08 NOTE Failure of the sealed inner gearcase bearing is unusual Do not remove this bearing unless it is damaged Inspection Figure 11 8 Removing the inner bearing E Carefully inspect all gears shafts splines and threaded areas for mechanical dam age or overheat
68. fore the pinion drive gear and bearings must be removed from the input end of the gearcase before the output shaft assembly can be removed from the housing Tools Required for Disassembly Use the gearshaft puller designed for Shin daiwa T C 250 and T 20 units but substitute the 8 mm puller bolt from the puller used for T C 25 and T C 27 units Refer to the Appendix for puller part numbers E Remove the cutting attachment and blade holders same as for all models Figure 11 18 E Remove the clamp screw and D shaped washer locating screw and gearcase filler plug Slide the gearcase assembly off the shaft tube E Remove the internal snap ring from inside the input driveshaft end of the gearcase Use snap ring pliers such as Snap On PR 23A or equivalent Figure 11 18 WARNING Always wear safety glasses when working with snap rings The output shat and gear cannot be disassembled for service The pinion gear and bearings must be removed before pulling the output shaft Figure 11 17 Shindaiwa 250 serles gearcase Figure 11 18 Remove the snap ring from the input end of the gearcase Shindaiwa Inc 1994 99 9 m gt JJ 0 gt 0 m 00 section 11 Gearcases Disassembly Pinion Gear and Bearing Removal Models T C 250 STEP 1 Use a screwdriver to gently spread continued the clamp at the input drive end of the gearcase STEP 2 Pre heat the gearcase to approxi mately 212 F
69. ft remove the seals with a threaded screw type puller such as Shindaiwa p n 22150 96600 seal Puller Figure 8 7 or Punch a small hole through the seal s metal shell and withdraw the seal with a slide hammer puller CAUTION A Never drill through a seal shell Chips or other drilling debris may lodge in crankshaft bearings and lead to early bearing failure Never allow puller tips or other tools to contact the crank shaft bearings Puller P N 22150 96600 Figure 8 7 Removing seal with a seal puller Shindaiwa Inc 1994 3 Ww 0 lt xX Z lt o O Ww Z TT Section O Engine Crankcase Bearing Inspection Bearing Removal Cleaning 74 Inspect both crankshaft bearings for damage or accumulated debris Figure 8 8 Carefully spin each bearing by hand Replace any bearing that feels rough or hangs up while being rotated NOTE Removing bearings for inspection is generally not necessary unless the powerhead has suffered a major internal failure or has in gested large amounts of debris If a bearing must be removed always replace it with a new one Shindaiwa recom mends that any replacement bearing be either the factory recommended part or a bearing of equivalent quality and fit from the same manufacturer STEP 1 Place the crankcase half face down on a clean wooden surface drilled to accommodate the crankcase locating pins STEP 2 Remove the bearings fr
70. ft tube flexible cable and liner are identical for both units M Ihe gearcase blade guard and wheel are all identical for both units IMPORTANT The model LE gearcase is not interchange able with the T C gearcases installed on Shindaiwa trimmers and brushcutters Unique Parts The following parts are unique to each model and are not interchangeable between the LE 230 and LE 250 WH Clutch shoes and drum E he powerheads are interchangeable between LE units they require appropriate throttle cable and stop switch but are not interchangeable with powerheads for trimmers and brushcutters Shindaiwa Inc 1994 Blade Holder Machine Screw Clamp tab Lockwasher must be down Washer Washer Figure 12 2 Parts unique to Shindaiwa LE 230 and LE 250 lawn edgers Lawn Edgers section 12 NOTE When in doubt as to interchangeability of specific components consult the appropriate Illustrated Parts List IPL WARNING Never attempt to modify a Shindaiwa trimmer or brushcutter for use as a blade equipped edger Notes on Service Service procedures for the powerhead and related component are the same as those for trimmers and brushcutters of the same engine series Refer to the appropriate sections of this manual E Gearcase service for both units is identical to gearcase service for the T C 250 See Section 11 CAUTION Disassembling the gearcase on either the LE 230 or the LE 2
71. gine Figure 10 1 Figure 10 1 Torsional relief section of the shaft CAUTON Do not remove plugs from hollow mainshaft ends Plugs are installed to prevent gearcase grease from travelling up the mainshaft tube Mainshaft Inspection Inspect the mainshaft for signs of unusual wear at each of the bushing locations Damaged E A normal mainshaft will display a slight Mainshaft stain or print where it turns in each bushing E Pitting scoring or galling on the mainshaft Figure 10 2 indicates a bushing failure In Figure 10 2 Inspect the mainshaft that event the mainshaft and all dam aged bushings must be replaced Shindaiwa Inc 1994 85 section 10 Mainshafts and Outer Tubes Mainshaft Inspection STEP 1 Inspect both mainshaft splines for damage or wear Figure 10 3 When in doubt compare spline depth and condition with that of a new shaft from the same model STEP 2 Verify mainshaft straightness by rolling the shaft on a flat surface or by rotating it in a straight length of angle iron Replace any shaft that is noticeably worn or distorted CAUTION Although an outer tube assembly will often return to shape after being bent or bowed through careless handling such abuse can permanently bend the mainshaft inside CAUTION A A bent shaft and or damaged splines can cause rapid wear of the softer clutch drum splines If you discover a bent shaft and or damaged splines
72. given in inch pounds Kgfcm Screw Location Size F T 18 F 20 T 20 T C 230 T C 250 ENGINE Crankcase 5mm 44 60 50 70 all models Cylinder to Crankcase 5mm 44 60 50 70 all models Cylinder to Carburetor Insulator 5mm 35 44 40 50 35 44 40 50 35 44 40 50 35 44 40 50 44 52 50 60 Flywheel 8mm 104 122 120 140 all models 10 mm Starter Hub on crankshaft 8mm 104 122 120 140 all models Muffler 5mm 52 70 60 80 44 60 50 70 44 60 50 70 44 60 50 70 52 70 60 80 6mm ne spark Plug 14mm _ 148 165 170 190 all models Clutch Shoe Bolt 6mm 60 90 70 100 Coil 4mm 35 44 40 50 Unit 4mm 17 26 20 30 26 35 30 40 Cylinder Cover amp Recoil Starter 4mm 13 22 15 25 26 35 30 40 5 mm Carburetor 5mm 35 44 40 50 all models TRIMMER BRUSHCUTTER ASSEMBLY Gearcase to Outer Tube 5 mm 52 60 60 70 6 mm 52 78 60 90 Handle Bracket 5 mm 52 60 60 70 6 mm 87 104 100 120 Clamp Outer Tube 5mm 35 44 40 50 52 60 60 70 Blade Holder 7mm 87 104 100 120 8 mm 104 120 120 140 10 mm Trimmer Head mm 8mm 52 87 60 100 Fan Cover 5 mm Screw Locking Agent Recommended Three Bond 1401 Screw Locking Agent Recommended Three Bond 1360 1 06 Shindaiwa Inc 1994 Appendix Oro ue Values section 13 Bolt Values given in inch pounds Kgfcm Screw Location size T C 25 T C 27 C 35 BP 35 B 40 B 45 RC 45 ENGINE Crankcase 5mm 44 60 50 70 44 60 50 70 60 70 70 80 60 70 70 80 Cylinder to Crankcase 5
73. gms Loosen the metering cover and pry out the cover are a check valve ulb Figure 3 21 Servicing the check valve Shindaiwa Inc 1994 35 Section 3 Walbro Carbu retors Dissassembling C Metering Diaphragm and Pump Walbro STEP 1 Gently peel the metering diaphragm Carburetors and gasket from the pump body casting continued STEP 2 Lift the pump body from the carburetor base and throttle assembly D Metering Lever and Inlet Valve Remove the metering lever retaining screw then carefully lift out the metering lever and pin inlet valve and metering lever spring E Pump Body Assembly If the inlet screen is to be cleaned or re placed gently pry it from the pump body Use care to avoid nicking or otherwise damaging either the screen retaining bore or the machined pump body mating surface F Venturi Body Assembly STEP 1 Use a small pick to gently pry the main jet and where used O ring from the venturi body assembly STEP 2 Turn the venturi body over and remove the two phillios head screws securing the throttle valve assembly U am O H Lu CC aa lt O STEP 3 Using hand pressure only carefully lift the throttle valve assembly from the venturi body G Throttle Valve Assembly STEP 1 Use a small pick to gently pry the plug from the center of the throttle lever This exposes the recess in which the inner idle needle is housed STEP 2 Using a small screw
74. he handle and remove the index screw from the rear handle grip Figure 10 10 STEP 2 Pull the flexible tube assembly from the rear handle and outer tube assembly STEP 3 Slide the flexible cable from the flexible tube assembly Figure 10 11 and Index va wash the cable thoroughly in a solvent screw bath Figure 10 10 Separate the flexible tube from the rear STEP 4 Inspect the cable carefully and handle grip discard if worn or damaged STEP 5 Use a rag to remove any excess grease from inside the rear handle grip Flexible assembly tube Cable CAUTION Excess grease in the rear handle assembly may cause the shaft tube to overheat SFT 04 STEP 6 Coat the entire length of the flexible cable with Shindaiwa Premium Gearcase Lube Reinstall the cable in the flexible tube assembly Figure 10 11 Remove the flexible cable STEP 7 During installation rotate the flex cable by hand to insure full engagement with the powerhead The remainder of the assembly is the reverse of disassembly CAUTION Inadequate lubrication can cause rapid wear of both the flex cable and liner resulting in increased vibration and greatly decreased service life gt Z 2 gt TI 2 GC W m 00 Flexible cables all units must be cleaned and relubricated at least every 50 hours of operation or whenever a unit is returned to service after extended storage Shindaiwa Inc 1994 91 00 Lu
75. he gearcase slightly during installion STEP 2 Install the pinion bearing snap ring IMPORTANT Snap rings are manufactured using a stamp ing process that produces a rounded or rolled edge on one side of the ring anda sharp 90 edge on the other The sharp edge of a snap ring must always face away from the bearing it retains Figure 11 11 Driver Snap ring groove Pinion and bearing assembly Figure 11 10 Installing the pinion and bearing Output driven Gear and Shaft Installation accempiy STEP 1 Using hand pressure only locate the output gear in the gearcase Figure 11 12 STEP 2 Insert the output shaft into the output gear STEP 3 Align the output shaft to the inner bearing by slowly rotating the shaft by hand STEP 4 Drive the shaft in place using the appropriate driver and a soft faced ham mer Verify correct installation and align ment by rotating the shaft by hand Toward bearing Output Seal and Snap Ring Installation pone tl ae NOTE Order of assembly is reversed for I 18 I 20 and later models of T C 27 Figure 11 13 on the following page STEP 1 Pre lubricate a new output shaft seal with Shindaiwa lithium based gearcase lube STEP 2 Use a soft faced hammer to start the seal in the gearcase bore STEP 3 Using the appropriate seal driver and a soft faced hammer seat the output shaft seal in the gearcase STEP 4 Place the output side snap ring
76. he shaft case output shaft to properly align its drive socket with the squared end on the flexible cable STEP 6 Install and tighten the shaft case index screw and then securely tighten the clamp screw CAUTON The flexible cable must fully engage both the powerhead and the output shaft drive sockets Incomplete engagement can shorten cable life drastically Straight Shaft and Gearcase M Service and maintenance procedures for the BP 35 gearcase are identical to those for all Shindaiwa straight shaft trimmers and brushcutters and are outlined in the Gearcase section M Service and maintenance procedures for the BP 35 outer tube and mainshaftt assembly are similar to those outlined earlier in this section except that the BP 35 outer tube requires only four bushings E Use Shindaiwa Bushing Driver p n 22000 96101 when servicing BP 35 outer tube bushings Correct spacing for BP 35 bushings is 11 02 280mm Shindaiwa Inc 1994 Tube Cable liner Shaft tube Shaft case housing Wb Clamp bolt oa Index bolt Shaft Bearing o O Nee Collar __ _ Bearing a aw Snap rin Collar Holder aii a Figure 10 9 Cable drive exploded view Mainshafts and Outer Tubes section 10 BP Stop 7 a Flexible Shaft Flexible switch Rear handle aintenance STEP 1 Unplug the two stop switch wires tube wires grip continued disconnect the throttle cable from t
77. ightly to fit the wider dimension of the new shaft Correct order of final assembly A choke plate B spring washer and C nut The choke shaft nut should be tightened only enough to provide reasonable resistance when activation the choke Do not rely on thread locking compounds to lock the nut THE CHOKE NUT MUST BE SECURELY STAKED TO THE CHOKE SHAFT THERE IS NO WARRANTY FOR INGESTED CHOKE NUTS 30 Shindaiwa Inc 1994 1012 2521 32 10092521100 1012 2521 32 not shown actual size Do Choke Shaft 11052312002 Spring Washer 11215452009 Nut 11078111008 TK Carburetors Section 3 Reassembling TK Carburetors IMPORTANT These are general service instructions only To verify the correct parts and component orientation for a specific model TK carburetor always consult the appropriate IPL A Main Jet Install the main jet and jet holder in the reverse order of disassembly lt For models with a one piece threaded main jet make sure the O ring is properly placed during jet installation B Inlet Metering Valve Lightly lubricate the metering valve with clean 2 cycle fuel and then install the valve in the carburetor body Install the spring metering lever and retaining screw in the reverse order of disas sembly Walbro tool p n 500 13 can be used to inspect for proper metering lever height Figure 3 16 IMPORTANT Metering lever height determines the level of fuel to be maintained in the
78. ing E Spin all bearings and discard those that feel rough loose or are difficult to spin E Inspect the gearcase for stripped threads damaged bearing bore or snap ring grove distortion or other physical damage M Discard any damaged or excessively worn component Reassembly IMPORTANT except Models Three special drivers are required for gear T C 250 case reassembly Gearcase tools are listed in the Appendix Do not attempt reassembly without the proper tools refer to the Special service Tools section of the Appendix Gearcase CAUTION Avoid bearing rebound Improp erly installed or poorly seated bearings can cause a gearcase to bind and may cause early gearcase failure Use a soft faced dead blow hammer when seating bearings Always drive bearings against a wooden block N or benchtop L 00 T Inner Bearing Installation Inner bearing Bearing driver an Using the appropriate bearing driver install F and seat the sealed inner bearing into the Figure 11 9 Installing the pinion and bearing gearcase Figure 11 9 assembly 96 Shindaiwa Inc 1994 GearcaSes section 11 Pinion drive Gear and Bearing Installation STEP 1 Hand fit the pinion and bearing assembly into the gearcase input end and use the appropriate driver to seat the assembly past the internal snap ring groove Figure 11 10 NOTE If installation is difficult use a heat gun to expand t
79. ing or discoloration E If in doubt about the condition of either component replace both parts as a set Reassembly Piston Crankshaft The piston pin is press fit into the piston and requires Careful installation to avoid damaging or distorting the piston or crankshaft assem bly Two methods are suggested here NOTE An assembly lubricant such as Never Seize can help minimize friction during the reassem bly process Uniformly heating the piston to no more than 100 C 212 F will also assist this process CAUTION After installing the piston on the crankshaft make sure the arrow Piston Piston Thrust Bearing Thrust Circlip boss pin washer washer _ slot area SNES on the piston crown points toward the exhaust muffler side of the engine EN Piston Crankshaft Reassembly Method 1 Using an appropriate alignment tool position the piston on the connecting rod with the needle bearing and thrust washers correctly oriented between the piston pin bosses Figure 7 11 Use a pin driver tool and a soft faced hammer to drive the piston pin into the piston Figure 7 11 Thrust washer and bearing orientation until it is centered between the two circlip slots MOSS CYL 22 Piston Crankshaft Reassembly Method 2 Use a suitable alignment pin to position the needle bearing and thrust washers as de scribed above Using pin puller tool p n 72182 96300 and a push pin press the piston pi
80. inspect the clutch drum splines by test fitting a new shaft as shown in Figure 10 4 IMPORTANT Proper bushing removal and installation requires Shindaiwa Bushing Driver p n 22000 96101 Bushing Removal CAUTION Proper use of the Shindaiwa Bushing Driver minimizes the risk of improperly positioned bushings or damage to the outer tube assembly 00 Lu m U H LL lt zE 00 lt Use Shindaiwa approved service tools only Makeshift bushing drivers such as wooden dowel rods or plumbing pipes can permanently damage the outer tube assembly STEP 1 Hold the outer tube vertically with its lower end pressed firmly against a scrap of wood placed on the floor STEP 2 Slide the bushing driver into the upper end of the outer tube and use the driver in a slide hammer fashion to force all five bushings against the wood scrap at the bottom end of the tube STEP 3 Lift the tube slightly and continue using the bushing driver The entire stack of bushings should slide from the tube Figure 10 5 86 Shindaiwa Inc 1994 Normal 3g SFT 06 Figure 10 3 Spline damage usually results from a bent or bowed mainshaft Figure 10 4 Inspect the clutch drum splines by test fitting a new shaft Figure 10 5 Use bushing driver p n 22000 96101 in a slide hammer fashion to force bushings from the shaft tube Mainshafts and Outer Tubes section 10 Bushing NOTE Removal Rem
81. ion temperatures same effect as pressing the lever on an acetylene cutting torch WH Outdated or low octane fuel can burn unevenly and unpredictably producing excessive combustion pressures that tend to have a hammering effect on pistons Figure 2 7 Shindaiwa engines require a fuel with an octane rating of at least 87 or above Unless stored fuel has been pre treated with an approved fuel stabilizer such as Sta Bil Shindaiwa advises against using any motor fuel stored over 30 days E Oxygenated fuels any fuel containing alcohol or ether based oxygenating compounds So called clean air fuels are blended to provide additional oxygen during the combustion process producing higher combustion temperatures similar to a lean carburetor adjustment For addi tional information on oxygenated fuels refer to the Fuel and Oil section of the Appendix E Air Leaks Air leaking past crankcase seals cylinder gaskets or impulse passages can dilute or lean out an engine s fuel air ratio and can produce the same effect as an improperly adjusted carburetor Overheating causes a piston skirt to expand and score heavily on the exhaust side of the cylinder toward the arrow and may produce similar but reduced scoring on the cooler intake side as well Figure 2 5 Damage caused by overheating Preignition typically melts the piston crown toward the exhaust side toward the arrow of the piston or may burn a
82. ion at cranking speed should be at least 85 psi or above An irregular idle soeed combined with erratic high speed performance can indicate outside air is entering the engine through a vacuum leak If you Suspect a vacuum leak pressure test the block as described in Section 2 22 Shindaiwa Inc 1994 Troubleshooting Carburetors secion3 Muffler Backpressure from a clogged muffler or spark arrestor can restrict an engine s high end performance or may prevent the engine trom firing or starting altogether Inspect the muffler and spark arrestor for carbon buildup and if necessary decarbonize as described in Section 9 Spark Spark A worn fouled misfiring or incorrectly sized Plug spark plug will affect engine performance and must be replaced before performing further troubleshooting procedures See also Ignition section 5 Fuel Quality Stale dirty or contaminated fuel must be completely purged from the tank filter fuel lines and carburetor before any further troubleshooting If dirt or debris has entered the fuel lines inspect the filter screen Walbro or remove and clean the main jet TK before continuing to troubleshoot When refilling use only clean fresh fuel with an octane rating of 87 octane or higher mixed with Shindaiwa Premium 2 cycle Engine Oil at a ratio of 40 1 3 2 oz oil per 1 gallon gasoline Refer to the Fuel and Oil Section in the Appendix SYOLAYUNEEVD Adjustments E Inspect idle screw
83. ires or connectors Check the magneto air gap Correct gap size 0 012 0 014 Check for correct parts and installation Refer to the Illustrated Parts List IPL Make sure required insula tors are properly installed under the magneto and or TOI Test the TCI unit with a kV meter Test the TCI 2 piece by substitution Test the coil for open or shorted windings Perfor mance test the coil with a kV meter or flywheel simulator U Lu 00 gt 00 lt Inspect for a sheared TT The following pages of this Section flywheel key affects timing provide additional details about only these Troubleshooting steps Figure 5 5 Troubleshooting the electronic ignition system 52 Shindaiwa Inc 1994 Ignition Troubleshooting continued Ignition Systems Section 9 Equipment Requirements Basic ignition troubleshooting requires an ohmmeter an adjustable gap spark tester Figure 5 6 and a systematic approach to the problem IMPORTANT Most ignition troubleshooting can be com pleted in five minutess or less and can be performed without disassembling the trimmer Many ignition problems are the result of faulty or corroded wiring or ground con nections On an industry wide basis over 50 of all ignition components returned for warranty have nothing wrong with them The Spark Plug E Remove the spark plug and inspect it for proper size gap and condition Spa
84. l ratio 40 1 all models Failure to use manufacturer s recommended oil ratios could void manufacturer s warranty See warranty policy for details CLUTCH Material Bonded Bonded Bonded Bonded Bonded Bonded Metal Bonded Bonded Number of Shoes 2 2 2 2 3 2 4 3 3 Number of Springs 1 1 1 1 3 2 4 3 3 RECOIL Housing material Diecast Diecast Nylon Nylon Diecast Diecast Diecast Diecast Diecast Attachment points 3 9 4 4 4 4 4 4 4 Cord diameter mm 3 0 35 35 35 4 4 4 4 4 Cord length mm 806 806 826 826 806 810 810 810 810 A C 35 brushcutter may be fitted with a 2 shoe 3 shoe or 4 shoe clutch assembly Refer to Section 6 and Shindaiwa Parts Revision No PR 115 1 06 Shindaiwa Inc 1994 Appendix Specifications section 13 IGNITION Ignition type Number of Components Minimum output voltage Coil flywheel air gap Ignition timing Spark plug recommended Spark plug alternative Spark plug gap MUFFLER Muffler type Attachment points ANTI VIBRATION Engine lower unit Front Handlebar Soft rear handgrip spring rubber on harness LOWER UNIT Drive Type Gearcase ratio Outer Tube Material Diameter Wall Thickness Overall Length Shaft Type Shaft cable diameter Shaft cable length Number of Bushings CONFIGURATION Loop front handle Handlebars Grip mounted throttle Handlebar throttle Grip stop switch Engine mtd stop switch WEIGHT Unit less accessories Ib kg T 25 C 25 T 27 C 27 C 35 STCI all models 2 2 d 1 2 18 kV
85. ld raise and lower smoothly with no side to side movement E Inspect the throttle lever and cable fitting for damage or unusual wear Replace if noted WH Inspect the idle stop screw lug for cracking or stripped threads If such damage is discovered replace the entire valve assembly D Main Jet and O Ring Damage to the main jet is unusual since the jet can be usually cleaned in solvent and then cleared with compressed air lt A replacment O ring is included with the Walbro gasket and diaphragm repair kit Shindaiwa Inc 1994 of U am O H Lu CC aa lt O Section 3 Walbro Carbu retors Inspecting E Pump Body Walbro E Inspect the pump body casting for damage Carburetors or corrosion Make sure the fuel inlet air continued purge tube and pasageway plugs are tightly in place If you discover any of these problems replace the pump casting E Use a straightedge to determine if the body s machined mating surfaces are warped If you discover warpage replace the pump casting CRB 21 Metering Valve E Inspect the inlet needle for signs of Normal Replace measureable wear or distortion at the tip or shank and replace if noted Figure 3 22 e When in doubt as to needle serviceabil ity reinstall the needle and lever assembly and pressure test for pop off and reseat as described on page 24 Figure 3 22 Inlet needle E Inspect the metering lever for signs of wear at the fork
86. lve or TK slide valve carburetor fitted with an integral fuel pump Noncurrent F 20 grass trimmers use a Walbro WA 135 butterfly valve carburetor During operation the fuel pump diaphragm responds to crankcase pressure pulses generated by the engine s moving piston The opposite side of the moving diaphragm then pumps fuel to a metering chamber located within the carburetor body Figure 3 1 Fuel levels in the metering chamber are maintained by a second diaphragm that actuates an inlet metering needle Figure 3 2 Fuel stored in the metering chamber enters the carburetor venturi bore through a throttle dependent needle seated in a jet or nozzle NOTE Both systems regulate air and fuel flow simultaneously allowing precise mixtures at any throttle setting Both TK and Walbro carburetors M Have impulse driven fuel pumps with internal check valves WH Store fuel within an internal metering chamber E Feature priming systems for purging air from the metering chamber during starting operations E Utilize a diaphragm operated inlet valve to maintain metering chamber fuel levels allowing either carburetor to function in an inverted orientation M Regulate fuel delivery by means of a throttle dependent needle and seat WE Feature an adjustable venturi area by means of a sophisticated throttle valve Beyond obvious physical differences how ever the Walbro and TK carburetors differ significantly in the meth
87. ly and perform the pop off and reseat pres sure test as described on page 24 Inspect the metering lever for signs of wear at the forks hinge pin or from contact with the diaphragm Figure 3 15 Wear in any of these areas will prevent the lever from being properly adjusted and is cause for rejection E Diaphragms Inspect diaphragms for cracks or leaks by placing over a lighted flashlight lens or microfiche screen A stiff or wrinkled diaphragm has likely been damaged by gasoline with a high alcohol content and must be replaced F Adjustment Screws Carefully examine adjustment screw tapers and threaded areas for signs of wear or damage Damage to either screws tapered surface requires careful inspection of the nonrenewable seats in the carburetor body and may require carburetor replacement G Priming Assembly Inspect the air purge valve for any wear or damage that might allow air or fuel leakage during operation Replace components as required E Examine the metal priming lever for bend ing or distortion at the forks and pivot area and replace any lever that cannot be straightened to compare with new parts M On 1 C 25 carburetors carefully examine the overflow purge valve s internal O ring seat and replace if hardened or damaged Normal Replace Figure 3 14 Inlet needle CRB 21 Wear areas Figure 3 15 Inspect the metering lever for wear Shindaiwa Inc 1994 29 SYyoO1JYNG
88. m element should be rinsed in mixed fuel and then squeezed dry before reinstal lation O CRB 25 CAUTION An engine that has been run with a damaged distorted or incor rectly assembled air filter or filter housing should be carefully inspected for internal PA yea Figure 3 6 Checking the insulator block for air leaks _ Air Leaks Pulse Check for air leaks at the insulator block and askets by applying a light film of oil Figure Passage an During see a change in DA Make sure the insulator passages are clear and that the holes in the gasket align with holes in the insulator block Do not use sealants to install insulator block gaskets or the carburetor rom indicates a vacuum leak 00 am O H Lu CC aa lt O CAUTION Never use starting fluid or other combustibles to search for air leaks Remove the insulator gasket Remove the carburetor and place a small drop of oil over the impulse passage If the impulse passage is clear the oil droplet should move rapidly in and out during engine cranking Figure 3 7 CAUTION Improper gasket installation or excessive use of Three Bond Place a droplet can block the impulse passage of oil here Insulator block Figure 3 7 Making sure the impulse passage is clear Low Low cylinder compression can cause hard Compression starting and poor performance and may be Vacuum Leaks mistaken for a carburetor problem Cylinder compress
89. mm 44 60 50 70 44 60 50 70 60 70 70 80 60 70 70 80 Cylinder to Carb Insulator 5mm 44 52 50 60 44 52 50 60 35 44 40 50 44 52 50 60 Flywheel 8mm 104 122 120 140 104 122 120 140 175 218 200 250 175 218 200 250 10 mm Starter Hub on Crankshaft 8mm 104 122 120 140 104 122 120 140 105 120 120 140 105 120 120 140 Muffler 5mm 52 70 60 80 52 70 60 80 6 mm 80 90 90 100 90 105 100 120 spark Plug 14mm _ 148 165 170 190 all models Clutch Shoe Bolt 6mm 60 90 70 100 all models Coil 4mm 35 44 40 50 35 44 40 50 44 52 50 60 44 52 50 60 Unit 4mm 17 26 20 30 17 26 20 30 Cylinder Cover amp Recoil Starter 4mm 26 44 30 50 26 44 30 50 5mm 26 35 30 40 26 35 30 40 Carburetor 5mm 35 44 40 50 TRIMMER BRUSHCUTTER ASSEMBLY Gearcase to Outer Tube 5 mm 6mm 52 78 60 90 52 78 60 90 90 105 100 120 90 105 100 120 p Handle Bracket 5mm 52 60 60 70 all models AL 6mm 87 104 100 120 all models z Clamp Outer Tube 5mm 52 60 60 70 all models J Blade Holder 7mm n 8mm 104 120 120 140 10 mm 175 190 200 220 175 190 200 220 Trimmer Head 7mm 8 mm m Fan Cover 5 mm 44 60 50 70 Screw Locking Agent Recommended Three Bond 1401 m Screw Locking Agent Recommended Three Bond 1360 00 Shindaiwa Inc 1994 1 09 Section 13 Appendix Toro Ue Values Bolt Values given in inch pounds Kgfcm Screw Location Size F T 18 F 20 T 20 T C 230 T C 250 ENGINE Crankca
90. models with a Metering slow air screw idle mixture remove the diaphragm 4 screw using a counterclockwise rotation assembly hy Cleaning STEP 1 Clean all parts in solvent then blow Purge bulb dry Figure 3 12 Exploded view of TK DP N carburetor used on Shindaiwa models T C LE 250 STEP 2 Clean all internal passages with compressed air If a commercial carburetor cleaner is used remove it and all residue immediately following its use with conven tional solvent CAUTION Commercial carburetor cleaners may remove protective internal coatings and casting fillers Use these cleaners only when absolutely necessary Shindaiwa Inc 1994 27 Section 3 TK Carbu retors Inspecting TK A General Carburetors Outright failure of any carburetor is unusual Most carburetor problems are caused by debris or other fuel related problems M Except for Model DP N the TK carburetor contains no internal filter Carefully inspect the main jet and all passageways for signs of clogging or debris E Diaphragms and other non metallic components can be damaged by exposure to stale fuel or by fuels with an unusually high alcohol content E Be alert for stripped fasteners or adjust ment screws as well as any hidden damage B Carburetor Body E Clear all passages with compressed air M Discard any carburetor body showing Worn grooves signs of distortion or other damage to any also make sure the E clip is not critical su
91. n into the piston until it is centered between the two circlip slots 68 Shindaiwa Inc 1994 Cylinders and Pistons section 7 lt Important Tip To aid in properly centering the piston pin preinstall one piston pin circlio opposite the driver tool then tap the pin into the piston until it just contacts the clio When centering the pin be careful not to damage the circlip or circlip groove with the hammer Piston Crankshaft Reassembly Method 3 Install circlip s with their open ends facing either at the six o clock toward crankcase or the twelve o clock position Figure 7 12 When you hear an audible click the circlio is seated To be sure visually inspect the clips with a magnifying glass As a final check verify proper seating by using a pick to gently force the circlip into the groove G gt End gap CAUTION lt lt U m JJ V x O Z 00 Retainer end gap must face toward either the 6 o clock or 12 o clock position Figure 7 12 Retaining ring installation Improper circlip positioning or installation can result in major engine failure Locating pins Cylinder Place a new base gasket on the crankcase Installation assembly CAUTION Figure 7 13 Locating ring end gaps Never use sealant of any kind when installing the cylinder gasket The cylinder base gasket must be installed dry Using hand pressure only carefully install individual piston
92. n tools only Base Gasket Use a sharp gasket scraper to remove hardened gasket material from the crankcase and cylinder base Figure 7 4 lt Baked on gaskets can be softened guickly by applying a small amount of commercial paint remover first Figure 7 4 Use a gasket scraper to remove hardened If the base gasket is stuck to the crankcase gasket material be very careful to avoid nicking or damaging the crankcase s aluminum sealing surface CAUTION sealing surfaces can easily be ruined by careless cleaning procedures Scrape old gasket material with a conventional gasket scraper only Never use a knife file or screwdriver to clean a sealing surface Aluminum Deposits Aluminum deposits that adhere to cylinder walls can be removed with muriatic acid a commonly available concrete cleaner CAUTION Read and follow the acid manufacturer s use and safety instructions Apply muriatic acid to chrome surfaces only Never allow muriatic acid to contact aluminum engine components as deterioration will be immediate Stubborn or glazed over deposits may need to be sanded first with a small section of fine emery cloth Shindaiwa Inc 1994 65 00 O 2 A 00 CC Lu m Z gt O section Cylinders and Pistons Piston Removal crown that is pointing towards the exhaust muffler side of the cylinder Figure 7 5 CAUTION The arrow on the piston crown ena
93. nd solvent to remove any oil or sealant remaining on crankcase assembly fasteners and mating surfaces STEP 2 Apply Liquid Gasket Coat both crankcase half mating surfaces with a thin even coating of 3 bond Liquid Gas ket Shindaiwa stock number 11 04 or use an equivalent Shindaiwa approved high temperature liquid gasket material Do not allow liquid gasket to run into bolt holes or inside the engine crankcase NOTE Liquid Gasket will not stick to oily surfaces Ww 0 lt xX Z lt o O Ww Z TT STEP 3 Install crankshaft in crankcase M E Install the crankshaft s tapered end into crankcase half M Avoid damaging crankcase seals with the sharp edges of the crankshaft keyslot Figure 8 20 E Gently tap the crankshaft with a plastic or other soft faced hammeruntil it seats in the crankcase bearing race Figure 8 20 Avoid contacting seals with sharp edges of the keyslot CAUTION Avoid cutting the crankcase seals on the sharp edges of the crankshaft s keyslot or threaded ends A cocked or otherwise off center crank case half installation may also cause a sealing lip to roll causing possible damage to or loss of its retaining spring 78 Shindaiwa Inc 1994 Engine Crankcase section 8 STEP 4 Install Crankcase S M Carefully slide crankcase half S over the crankshaft and align its locating pins with the corresponding holes
94. ndaiwa Inc 1994 39 Section 3 Walbro Carbu retors Installating STEP 1 Connect the throttle control wire Walbro STEP 2 Place a new carburetor mounting Carburetors gasket on the insulator block Make sure the insulator block impulse passageway and gasket are properly aligned then assemble the carburetor and air filter to the insulator block with the two carburetor mounting screws CAUTION The carburetor mounting gasket must be installed dry Use of silicone or other sealants can block the insulator impulse passage A blocked impulse passage can restrict fuel deliv ery possibly leading to serious engine damage STEP 3 Install the fuel and priming dis charge lines and hose retainers in the reverse order of disassembly STEP 4 Reinstall any covers or ducting removed during disassembly STEP 5 Fill the fuel tank with fresh 2 cycle fuel Start the engine and adjust the idle mixture as described at the beginning of the Walbro Carburetor section of this chapter U am O H Lu CC aa lt O STEP 6 Adjust low idle engine speed using a reliable tachometer Refer to the per model specifications in the Appendix AO Shindaiwa Inc 1994 Walbro Carburetors section 3 Walbro WZ A High Speed Mixture Adjustment CAUTION Carburetors STEP 1 Preset the high soeed mixture U j Figure 3 25 screw to 1 1 2 turns counter clockwise Pena or PEREN ad from the fully closed clockwise posi
95. ods used to perform routine service adjustments Shindaiwa Inc 1994 FUEL OUTPUT 3 Moving diaphragm pumps fuel to the carburetor metering chamber 2 Pressure impulses cause the fuel pump diaphragm to move 1 Moving piston creates alternating pressure pulses in the crankcase FUEL INTAKE Moving diaphragm pulls fuel into the pump chamber Figure 3 1 Fuel pump operation typical Fuel from the pump Regulated Fuel Pressure Pressure Figure 3 2 Air pressure against the metering diaphragm balances fuel pressure from the pump to maintain a constant fuel level within the metering chamber The system provides the carburetors main Jet or nozzle with a constantly metered fuel supply and will function in any position Carburetors General Information section 3 Carburetors By The following is a list of carburetors used on Application A Shindaiwa trimmers and brushcutters to ate Three basic types of carburetors are used on Shindaiwa trimmers brushcutters and edgers Butterfly Rotary and Slide Valve Carburetors used on all models except the BP 35 feature a metering chamber with a diaphragm for all position operation BP 35 carburetor uses a conventional float valve metering system Model Manufacturer Type Carburetor Model F 18 TK Slide DPK8W F 20 Walbro Butterfly WA 135 F 21 Walbro Rotary WY 24B 1 18 TK slide WYP DPK8W T 20 early Walbro Rotary WZ8C T 20 late TK Slide DPV 10W T
96. oltage causes the TCI to abruptly switch off The magnetic field collapses when the TCI switches off and the moving magnetic field induces a high voltage in the secondary windings Secondary voltage rises only until it can jump the spark plug gap and complete the circuit to ground Shindaiwa Inc 1994 51 Section D Ignition Systems Construction All Shindaiwa trimmers and brushcutters use a transistorized TCI ignition system powered by a flywheel driven magneto Figure 5 4 Both initial timing and spark advance are controlled by the TCI unit and a mechanical on off switch or button is the only operator control provided solid state components within the TCI are protected from moisture and damage by an elastomeric potting compound They are shielded either within a separate metal or plastic case orare combined with the 2 piece system magneto to form a one piece assembly since wear prone mechanical breaker points and rubbing blocks are eliminated a TCI ignition will often outlast the equipment it s installed on 1 piece features a built in IC integrated circuit chip Figure 5 4 Shindiawa TCI ignitions systems Ignition Troubleshooting Test the switch A properly working switch passes Current in the off position only lest high voltage output with a gap tester or kV meter Check the spark plug for proper size and condition Clean and tighten all connections and grounds Inspect for damaged w
97. om each of the two crankcase halves using the appropriate bearing driver and a heavy hammer Figure 8 9 f bearings are difficult to remove the crankcase bearing bore can be expanded Slightly by using a heat gun to heat the bearing boss area to approximately 100 C 212 F See Figure 8 10 Carefully clean all mating and sealing sur faces Figure 8 11 lt Use acetone or a commercial gasket compound solvent to remove dried gasket compound deposits and to clean bearing bores Paper gasket residue can usually be softened with paint remover When using a scraper or other edged tool be extremely careful not to nick or scratch crankcase sealing surfaces CAUTION Do not allow acetone or paint remover to contact your skin Always wear gloves when working with solvents Always follow solvent manufacturer s directions and cautions for proper use cleanup and disposal Shindaiwa Inc 1994 Normal Dirt or accumulated Missing and or bearing debris Replace damaged components Replace Figure 8 8 Inspect bearings visually and manually Shindaiwa engines are high performance engines and require premium bearings for maximum performance and service life Figure 8 11 Use a gasket scraper to remove hardened gasket material Engine Crankcase section 8 Bearing Bearing installation is easiest if the crankcase Driver Installation bearing bore is first expanded slightly with
98. on chamber during the transfer process E Oil in the fuel air mix coats all internal parts including cylinder walls crankshaft and bearings WE In addition the atomized fuel mixture absorbs heat as It enters the crankcase lowering the engine s operating tempera tures 2 Compression The piston continues to move upward closing off all ports above the piston crown The air fuel mixture introduced during the previous revolution s transfer cycle is now trapped in the combustion chamber and compressed 3 Ignition As the piston approaches the cylinder head the spark plug fires and ignites the fuel air mixture To compensate for increases in engine rom the spark timing is advanced electronically 8 Shindaiwa Inc 1994 Exhaust and transfer ports closed Spark plug A A gt Compression Combustion Intake port open Crankcase Vacuum Figure 2 1 Crankcase vacuum is created during the compression stroke As the piston uncovers the intake port a fresh fuel air mixture is drawn into the crankcase When the spark plug fires the compressed mixture above the piston ignites and begins to expand Troubleshooting Ihe 2 Stroke Cycle ENGINE section 2 4 Power combustion The fuel air mixture expands rapidly forcing transfer ports the piston down the cylinder Piston movement Intake port open is transferred to the crankshaft through the closed connecting rod turning the crankshaft 5
99. onstruction with machined mating surfaces is standard and replacement crankcase halves are available as individual part numbers Crankshafts are supported by large ball bearings pressed into individual crankcase halves and mate to clutch and flywheel assemblies via Woodruff keys installed in machined key slots Introduction NOTE Crankcase halves are identified by either an M or S following the part name S refers to the crankcase half located on the recoil starter side of the engine M refers to the half used on the magneto output side of the engine Ww 0 lt xX Z lt o O Ww Z TT Remove Accessories STEP 1 Remove the cylinder cover and related shrouding Remove the piston and cylinder as described in Section 7 STEP 2 Remove the fan cover clutch assembly and flywheel as described in Section 6 STEP 3 Remove the recoil assembly and starter pulley as described in Section 4 STEP 4 Use diagonal pliers to remove the crankshaft woodruff key Figure 8 2 Crankcase Disassembly Separate the Crankcase STEP 1 Use a 4 mm allen wrench to remove the 3 or 4 bolts securing the two crankcase halves early model T F 20 with phillips head fasteners require a No 2 tip STEP 2 While firmly holding crankcase half S gently tap crankcase half M with a soft faced hammer Figure 8 3 STEP 3 As the crankcase halves begin to separate gently tap the crankshaft from c
100. or locate the cylinder in the case assembly can result in lower overall crankcase performance increased wear high engine temperatures and excessive stress on internal components Torquing Use a torque wrench Figure 7 16 to torque the cylinder bolts to the specifications listed in the Appendix Figure 7 16 Torque cylinder retaining bolts to the specifications listed in the Appendix 70 Shindaiwa Inc 1994 Cylinders and Pistons section 7 Final Assembly STEP 1 Install the muffler as described in Section 9 STEP 2 Install carburetor and reconnect fuel lines and control cables as described in Section 3 lt Z U m JJ V Z O Z STEP 3 Install the cylinder cover spark plug if removed and fit the high tension lead IMPORTANT A rebuilt engine can run slightly hotter than normal until new parts conform or seat against each other This is caused by initial friction and temporary blow by between new piston rings and cylinder walls Shindaiwa recommends that after any rebuild M the engine s carburetor be adjusted slightly rich E the engine be operated at varying speeds and reduced loads for approximately 10 hours Shindaiwa Inc 1994 71 Section O Engine Crankcase All Shindaiwa trimmer and brushcutter crankcases feature diecast aluminum alloy construction for longest service life and maximum durability Figure 8 1 Gasketless two piece c
101. oval of stubborn bushings may require continued striking the driver with a or mallet or dead blow hammer Bushings may drive more easily if first treated with a lightweight oil such as WD 40 Jo avoid spreading grease during bushing removal wrap the end of the shaft tube in rags or paper Bushing and Tube Inspection STEP 1 Inspect the outer tube Discard any tube that is cracked distorted or bent STEP 2 Carefully inspect the bushings and rubber a v mountings Discard if worn or damaged Assembly Bushing Installation Installation technique is similar to removal except that bushings are installed individually CAUTION from the center of the tube out Figure 10 6 Bushing depth is critical to overall A lightweight oil such as WD 40 can greatly performance Improper bushing ease the installation process depth may induce shaft vibration and can damage the mainshaft and bushings Bushings work outboard from the center bushing Shaft tube V gt TI L GC W m Bushing driver is marked for nee correct bushing placement Bushing driver Bushing Locations mm Model A B C D E T LT 18 T C 230 240 490 240 490 740 T C 20 T C 25 T C 27 T C 250 240 490 240 490 740 C 35 B 40 B 45 RC 45 223 456 223 456 690 BP 35 Four bushings used measure equal 280 mm increments from the gearcase Figure 10 6 The use of a bushing driver ensures proper bushing alignment and spacing Shindai
102. per and the flywheel bore M Carefully inspect the woodruff key and the key slots on the crankshaft taper and the flywheel Replace worn or damaged parts as required E Examine the flywheel casting magnet and insert if fitted If you discover any dam aged or loose components replace the flywheel as an assembly NOTE Missing flywheel fins are often the result of operator abuse sticks or other trash jamming in the flywheel and can also indicate a bent or distorted crankshaft If you Suspect crank shaft damage see inspection procedures described in Section 8 CAUTION Never attempt to reuse a flywheel that has damaged or missing fins Flywheel fins are critical to both engine cooling and balance Reassembly STEP 1 Install woodruff key p n 22100 43210 same for all models in the crankshaft keyslot STEP 2 Carefully fit the flywheel over the crankshaft and onto the woodruff key Use a soft faced hammer to firmly seat the flywheel on the crankshaft CAUTION A The flywheel must be installed dry Use no oil or other lubri cants when assembling flywheel to the crankshaft STEP 3 Making sure the woodruff key is properly placed install and torque the flywheel attachment nut to the specifica tions listed in the Appendix STEP 4 Rotate the flywheel by hand and make sure it turns true Inspect and adjust the magneto air gap as described in Section 5 STEP 5 Install the clutch assembly f
103. piston stop or short length of starter cord to lock the flywheel in position Figure 6 5 STEP 3 Remove the clutch shoe shoulder bolts same as 2 shoe Clutch Assemblies by Model No Model Shoes Assembly P N Spring P N F 18 2 70000 51103 70000 51220 1 18 2 20035 51100 20035 51221 F 20 2 70000 51103 70000 51220 F 21 2 70000 51103 70000 51220 T C 20 2 20035 51000 20035 51221 F T C 230 2 70140 51100 20035 51221 T C 250 2 20018 51000 20018 51220 T C 25 2 20000 51103 20000 51220 Direction of rotation Direction of rotation Trailing shoe installation Leading shoe installation Figure 6 3 Shoe orientation determines both clutch engagement rate and performance To remove Clutch tool P N 20000 96411 Figure 6 4 Using the clutch tool Plastic Stop Figure 6 5 Two methods of locking the flywheel No T C 27 2 C 35 C 35 C 35 BP 35 B 40 B 45 RC 45 WOW AM BWP Shindaiwa Inc 1994 20024 51100 20014 51100 20021 51100 20020 51100 20050 51101 20020 51100 20021 51100 20021 51110 Starter Cord Model Shoes Assembly P N Spring P N 20024 51220 20010 51120 20021 51120 20020 51131 20050 51121 20020 51131 20021 51120 20021 51120 59 2 2 ae 7 lt m m section Clutches and Flywheels Clutch Removal Models With 4 Shoe Clutch continued STEP 1 Lock the engine flywheel STEP 2 Remove the two countersunk screws securing the cover pla
104. ports WE if you discover cylinder bore wear measure the bore with a micrometer and telescoping gauge Figure 7 3 Replace any compo nents distorted or worn beyond the toler ances listed in the Appendix CAUTION Never install a used piston ina new cylinder Always verify cylinder condition before reassembly Never attempt to install a new piston ina used cylinder that is damaged distorted or is worn beyond specified tolerances Shindaiwa Inc 1994 Pin boss area Piston Thrust control Piston washers pin eo Retainers Bearing Figure 7 1 Piston and pin assembly Eii aN Remove four 4 base screws amp ZE on T 25 and wA larger two on So T 230 and SSR smaller a co AN Ng beh a4 Figure 7 2 Removing cylinder base screws Measure cylinder bore taper Measure at two points minimum Figure 7 3 Mesuring with an inside micrometer Cylinders and Pistons section 7 Cleaning Decarbonizing Examine the exhaust port and combustion chamber for signs of carbon buildup Use a plastic or wooden scraper to remove carbon deposits IMPORTANT The cylinder must be removed from the engine and separated from the muffler for proper inspection or decarbonization lt lt U m JJ V O Z 00 CAUTION Never use metal tools wire brushes or abrasives to remove carbon deposits Decarbonize cylinders with plastic or woode
105. rag preloading a Excessive drag can usually be elimi nated by sharply tapping the input end of Tap sharply with a a Reassembly Assembly is basically the reverse of JI NGGI Figure 11 22 Seat the outout shaft and gear assembly Outer bearing Snap ring the gearcase with a soft faced hammer SOK hammer Figure 11 24 STEP 2 Prelube and install the gearcase CS output shaft seal 6 Lubrication E Lubricate the gearcase with Shindaiwa Premium Gearcase Lube and install the gearcase plug and collar Figure 11 24 Removing excess drag from the 250 Gearcase Installation gearcase G m gt JJ 0 gt U m 0 mM Assemble the gearcase to the shaft and reinstall holders and cutting attachment Shindaiwa Inc 1994 101 Section 12 Lawn Edgers General Common Parts Figure 12 2 102 Gearcase peice PIEDE Edger Blade Powerhead Stop Switch P A Sg eo Throttle Trigger Figure 12 1 Major components of a Shindaiwa LE series lawn edger LE 250 shown The 230 series and 250 series lawn edgers are based on standard Shindaiwa powerheads Both machines turn a solid steel edging blade by means of a flexible cable and gearbox The LE series machines offer a powerful and lightweight alternative to edging with string trimmers or bulky three wheeled machines Figure 12 1 The following parts are interchangeable between the LE 230 and the LE 250 edger E The sha
106. rankcase half S CAUTION A Never insert knife blades or other tools between the crankcase mating surfaces A screwdriver may be used only where separation slots have been provided Figure 8 4 T2 Shindaiwa Inc 1994 Crankcase M Seal Crankcase bearings Crankcase screws Locating pin Seal Figure 8 2 Removing the Woodruff key from the crankshaft Separate crankcase halves by gently tapping half M at the places shown with the triangle Figure 8 3 Tap crankcase halves with a hammer Use a screwdriver only where separation slots are provided Separation Slot Figure 8 4 Separate halves at the separation slot only Engine Crankcase section 8 Crankcase Carefully inspect crankcase halves for cracks Inspection or other damage Carefully inspect crankcase mating surfaces and cylinder base surface for nicks scratches or other damage that might cause leakage or misalignment during operation CAUTION Make sure the crankcase locating pins are correctly press fit into crankcase half M Figure 8 5 ASVOMNVED ANIDSNSA Removing E With the Crankshaft Removed Crankcase Seals Pry the seals from the crankcase halves using either a hook type seal remover or a screw driver blade Figure 8 6 CAUTION Avoid scratching or nicking the crankcase seal bore E With the Crankshaft In Place If a seal puller will slide over the cranksha
107. re USFS type spark arrestor screens and screens can be easily removed for cleaning or replacement as required Figure 9 1 Service Trimmer orushcutter spark arrestor screens are susceptible to clogging over time and should be inspected on at least annually More frequent inspection is required if an engine is operated with rich oil fuel ratios excessively rich carburetor adjustments or is operated at low RPM for long periods of time IMPORTANT Hard starting gradual power loss and poor high RPM operation may indicate a clogged arrestor screen U am Lu TH TH Spark Arrestor Muffler inspection and decarbonization can be performed with the muffler installed on the nemoval powerhead STEP 1 Remove the spark arrestor cover screws then remove the cover and lift out the spark arrestor screen STEP 2 Burn carbon deposits from the screen with a propane or acetylene torch or remove deposits by soaking the screen in an oven cleaner followed by a thorough cleaning in a solvent bath WARNING Oven cleaner is highly corrosive and should never be used without proper eye respiratory and skin protection Read and follow the manufacturer s use and safety precau tions when working with oven cleaner Never allow oven cleaner to contact aluminum parts Oven cleaner can quickly corrode and ruin aluminum 80 Shindaiwa Inc 1994 Mufflers Section 9 Spark arrestor Muffler cover Muffler
108. ree Bond 1304 or equivalent prior to installation STEP 2 Drive In the new seal Drive the new seal flush with the outer face of the seal bore using the appropriate seal driver and a plastic or dead blow hammer Figure 8 15 Carefully inspect the completed installa tion A seal that contacts the inner bearing race or is bent or damaged in any way must be replaced CRK 17 Figure 8 14 Pre lube seals prior to installation Make sure seal is flush with the outer face of the seal bore Figure 8 15 Seal in the crankcase bore Shindaiwa Inc 1994 T9 WW 0 lt O X Z lt o O WW Z O Z TT Section O Engine Crankcase Crankshaft Inspection Figure 8 16 76 Carefully inspect the crankshaft before reassembly especially if the engine suffered a major component failure or sudden stoppage A crankshaft assembly that fails in any of the following areas should be replaced E Crankshaft bearing seal contact surfaces Inspect for wear or burnishing at both crankshaft bearing and seal contact surfaces Wear must not exceed the tolerances listed in the Appendix E Connecting rod big end bearing 1 Check for signs of roughness or irregu larity within the big end bearing by rotating the rod slowly around the crankshaft 2 Slide the connecting rod from side to side and note any excessive drag inspect both the needle bearings and cage for damage NOTE A damaged crankpin can cause ratche
109. rface including mating flanges distorted threaded holes cap and slide bore Be especially alert for bending or other damage to the air filter mounting area This type of damage can cause air leakage the carburetor should be replaced C Slide Needle Main Jet Needle Worn Examine the throttle slide valve for signs of NGENE pitting or other mechanical damage Slide bore wear can be caused by operating an engine with a missing or damaged carburetor cable boot which allows unfiltered air to leak past the cable and slide The carburetor body is not available separately so any carburetor with a damaged slide valve bore must be replaced O ring as an entire assembly E Examine the jet needle and be especially alert for any indication of wear at the needle taper and also at the grooves for the needle retaining clip see Figure 3 13 U am O H Lu CC aa lt O Check for a worn jet WH Whenever wear is discovered at either the Jet needle or jet replace both components as an assembly IMPORTANT If the jet needle shows visible wear replace both jet and needle as an assembly CRB 18 Figure 3 13 Jet and needle I 25 shown 28 Shindaiwa Inc 1994 TK Carburetors Section 3 D Metering Valve Assembly E Inspect the inlet needle for signs of wear and replace if you discover measurable wear Figure 3 14 e When in doubt as to needle serviceabil ity reinstall the needle and lever assemb
110. rings and align each with its appropriate locating pin Figure 7 13 Lightly lubricate both the piston assembly and cylinder walls with a suitable assembly lubricant Piston Ring Installation Using a ring compressor Figure 7 14 or by compressing rings with finger pressure carefully slide the cylinder over the piston vi TLL T1 JING CAUTION Cylinders must be installed with the arrowhead on the piston crown facing the cylinder s exhaust port Improper cylinder orientation or attempt ing to rotate the cylinder on the piston will cause piston rings to hook and fracture in the cylinder ports Figure 7 14 Compressing rings while installing pistons in the cylinder Shindaiwa Inc 1994 69 section Cylinders and Pistons Cylinder Install Cylinder Bolts Installation Coat the cylinder bolt threads with Three continued Bond Liquid Screw Lock or equivalent and aera 00 O 2 A 00 CC Lu m ra gt O tighten each bolt only until it just contacts the cylinder base less about 1 2 to 3 4 turn Cylinder Alignment With one hand on the cylinder center or locate the cylinder in the crankcase by slowly rotating the crankshaft while checking for binding Figure 7 15 When you find the proper cylinder location hold the cylinder firmly while tightening the cylinder bolts in Sequence IMPORTANT Failure to properly locate the cylinder crank Figure 7 15 Center
111. rk plug wire terminal YES If the plug is wet excess fuel may be in the cylinder Is the spark plug firing properly The plug may be fouled or improperly gapped The plug may be damaged internally or the wrong type Remedy Refer to the Recoil Starter Section Refer to the Carburetor Section Refer to the Engine Crankcase and also the Cylinder and Piston Sections Tighten and re test Refer to the Cylinders and Piston Section Re till with fresh fuel of the correct mixture Shindaiwa Premium 2 cycle Engine Oil and gasoline 40 1 ratio Refer to the Appendix Section 13 Re start Refer to the Carburetor Section Move switch to ON and re start Refer to the Ignition Section Refer to the Ignition Section Crank the engine with the plug removed replace the plug and re start Clean and re gap the plug to 0 24 inch 0 6 mm Re start Replace the plug with a Champion CJ8 Re start Shindaiwa Inc 1994 1 1 JJ O Cc W m m 00 O O lt section 2 Troubleshooting Troubleshooting LOW POWER OUTPUT Guide Symptom Possible Cause Remedy Operator is overworking Adjust trimmer line Cut at a slower rate the machine Is the engine overheating Carburetor mixture is Adjust the carburetor For proper too lean procedures refer to the Carburetor and Specifications Sections Improper gas oil ratio Re fill with fresh fuel of the
112. rk plug condition is critical to the perfor mance of any ignition system A plug with a worn fouled or improperly gapped electrode requires a higher firing voltage and may cut out under load when its required firing voltage approaches the maximum voltage available from the ignition system Figure 5 7 All current model Shindaiwa trimmers and brushcutters are rated for a Champion CJ8 series spark plug gapped to 024 0 6 mm Always check proper plug size and gap in the appropriate owner s manual or in Shindaiwa publication 50537 0 CAUTION Spark plug heat range and dimensions are critical to the performance and lifespan of any gaso line engine Always make sure the correct plug is installed and properly gapped Installing a spark plug with a lower heat range than specified may cause excessive carbon buildup from incomplete combustion Installing a plug with a higher heat range than specified may cause pre ignition and can shorten engine life significantly Meter PETTI OFF CHECK CONT Spark gap tester Jumper leads Figure 5 6 Basic Ignition Troubleshooting Equipment Fouled Gap too large A A Worn electrode A OF loads Shindaiwa Inc 1994 IGN 28 Figure 5 7 Spark plug troubleshooting A plug with a worn fouled or improperly gapped electrode requires a higher firing voltage and may not fire under heavy 99 O O lt U lt
113. s hinge pin or from contact with the diaphragm Figure 3 23 Wear in any of these areas will prevent the lever from being properly adjusted Replace the lever Diaphragms Inspect diaphragms for cracks or leaks by placing them over a lighted flashlight lens or microfiche screen A stiff or wrinkled diaphragm has likely been damaged by gasoline with a high alcohol content and must be replaced Wear areas Figure 3 23 Inspect the metering lever for wear Adjustment Screws Examine the idle stop screw and replace if bent or otherwise damaged he inner idle needle isnt considered a wear part and is not available separately Air Purge Priming Assembly E Inspect the air purge bulb and check valve for deterioration Replace components as required E Inspect the primer pump body for cracks or physical damage Replace if noted 30 Shindaiwa Inc 1994 Walbro Carburetors section 3 Reassembling A Throttle Valve and Venturi Body Walbro STEP 1 Install the inner idle screw and Carburetors spring in the reverse order of disassembly E Initial settings for the inner idle adjustment screw vary between models and are listed at the beginning of the Walbro Carburetor section Make settings from initial thread engagement during inner idle screw installation STEP 2 Replace the throttle valve assembly on the venturi body then install and tighten securely the two throttle valve collar screws STEP 3 Using hand pre
114. s and adjustable jets for and Controls proper adjustment Reset to the specifica tions listed in the Appendix E f tapered needle adjustments appear to have been impacted or overtightened inspect both needle and seat for damage CAUTION Forks The TK low speed mixture air bleed screw adjustment seats directly into the aluminum carburetor body Overtightening this screw can permanently damage the aluminum seat requiring carburetor replacement E Inspect the carburetor exterior for signs of visible damage E Verify smooth and full range throttle operation A cracked or missing cable boot ona TK carburetor can allow air and dirt to enter the carburetor around the slide valve ruining the carburetor and possibly damag ing the engine as well E Replace damaged or missing choke components M Inspect primer assemblies for leaks and Primer lever especially TK for damaged primer levers or forks Figure 3 8 Figure 3 8 TK primer lever typical Shindaiwa Inc 1994 23 U am O H Lu CC aa lt O section Troubleshooting Carburetors Sticking Valves Leaks 24 Use Walbro tool p n 57 11 or equivalent to test the inlet needle assembly for proper pop off and reseat pressures Figure 3 9 M The pop off value indicates the pressure required to overcome the inlet needle spring and should be for Walbro carburetors approximately 30 10 psi for TK carburetors approxima
115. screws Overtighten B 40 0 3 4 2 3 4 1 4 ing these screws can damage the B 45 0 1 2 2 1 2 1 4 adjustment seats inside the carburetor body requiring carburetor replacement Installing and STEP 1 Assemble the slide and needle in Adjusting TK the exact order as shown in Figure 3 18 Carburetors WE Make sure the needle retainer is correctly placed between the jet needle and spring and that the jet needle clip is properly positioned standard position is in the middle groove WE Making sure the rubber throttle cable boot is in good condition and is in place on the Spring carburetor cap install the throttle cable into the slide and needle assembly in the reverse order of disassembly Retainer ee NOTE cS Prior to carburetor installation the carburetor should be pressure tested for pop off and reseat pressures as described in the Trouble Jet Needle shooting Section of this Chapter In addition leak test the carburetor body by pressurizing the carburetor in a small can of solvent Slide STEP 2 Using a new gasket assemble the carburetor to the insulator block and firmly tighten the carburetor mounting screws TK carburetor model DP N is boot mounted and does not use a gasket Figure 3 18 Slide and needle assembly E ring 32 Shindaiwa Inc 1994 TK Carburetors Section 3 CAUTION The carburetor mounting gasket must be installed dry Use of silicone or other sealants can block the insulator
116. se 5mm 44 60 50 70 all models Cylinder to Crankcase 5mm 44 60 50 70 all models Cylinder to Carburetor Insulator 5mm 35 44 40 50 35 44 40 50 35 44 40 50 35 44 40 50 44 52 50 60 Flywheel 8mm 104 122 120 140 all models 10 mm Starter Hub on crankshaft 8mm 104 122 120 140 all models Muffler 5mm 52 70 60 80 44 60 50 70 44 60 50 70 44 60 50 70 52 70 60 80 6mm spark Plug 14mm _ 148 165 170 190 all models Clutch Shoe Bolt 6mm 60 90 70 100 Coil 4mm 35 44 40 50 Unit 4mm 17 26 20 30 26 35 30 40 Cylinder Cover amp Recoil Starter 4mm 13 22 15 25 26 35 30 40 5 mm Carburetor 5mm 35 44 40 50 all models TRIMMER BRUSHCUTTER ASSEMBLY Gearcase to Outer Tube 5 mm 52 60 60 70 Ht 6 mm 52 78 60 90 D Handle Bracket 5 mm 52 60 60 70 6 mm 87 104 100 120 x Clamp Outer Tube 5mm 35 44 40 50 52 60 60 70 5 Blade Holder 7mm 87 104 100 120 O 8 mm 104 120 120 140 x 10 mm T Trimmer Head mm x lt 8mm 52 87 60 100 O Fan Cover 5 mm z Screw Locking Agent Recommended Three Bond 1401 Ai Screw Locking Agent Recommended Three Bond 1360 lt 1 10 Shindaiwa Inc 1994 Appendix lorque Values section 13 Bolt Values given in inch pounds Kgfcm Screw Location Size T C 25 T C 27 C 35 BP 35 B 40 B 45 RC 45 ENGINE Crankcase 5mm 44 60 50 70 44 60 50 70 60 70 70 80 60 70 70 80 Cylinder to Crankcase 5mm 44 60 50 70 44 60 50 70 60 70 70 80 60 70 70 80
117. settings are provided in the Appendix E Sustained engine overload resulting in low rom operation Shindaiwa Inc 1994 61 P Cc O 7 lt 2E m m rr Lu Lu T LL Lu TE O H O section Clutches and Flywheels Servicing the STEP 1 Remove fan cover and related Flywheel ducting as required Remove the clutch shoe assembly as described previously in this section STEP 2 Lock the crankshaft and flywheel with an appropriate piston stop Remove the flywheel nut turn counterclock wise CAUTION Do not use air impact or other power tools to remove flywheel nuts Crankshafts can be permanently Flywheel puller for the damaged by use of impact or other part number refer to the high torque tools Appendix Section 12 Figure 6 10 Removing the flywheel STEP 3 Use an appropriate puller to remove the flywheel from the crankshaft Refer to the Special Tools Section of the Appendix Figure 6 10 A CAUTON Never use striking tools to service flywheels Use of hammers or other striking tools can damage the flywheel and may also distort the crank shaft STEP 4 Use diagonal pliers to remove the woodruff key from the crankshaft Figure 6 11 Figure 6 11 Removing the woodruff key with diagonal pliers 62 Shindaiwa Inc 1994 Clutches and Flywheels section 6 Inspection WH Use a degreasing solvent to clean the Cleaning crankshaft ta
118. ssure only assemble the main jet and O ring then install the jet in the venturi body B Pump Body Assembly M f the fuel inlet screen has been removed install a new screen 0 059 inch E Install the pump diaphragm and gasket in the reverse order of removal then fit the oump body to the venturi body assembly SYOLAYUNEYVD C Metering Lever and Inlet Valve STEP 1 Lubricate the inlet valve with a few drops of fresh fuel mixture then install the valve spring metering lever and pin secure them all by firmly tightening the phillios nead metering lever screw STEP 2 Adjust the metering lever height to 0 059 0 005 using a Walbro gauge p n 500 13 or a straightedge and thickness gauge Figure 3 24 D Metering Diaphragm and Pump STEP 1 Install the diaphragm gasket and Figure 3 24 lo measure the metering lever height place a straightedge across the pump body casting purge body on the pump body assembly The metering lever should be 0 059 005 below the STEP 2 Using finger pressure only install straightedge Slight pressure will bend the metering the check valve lever up or down for adjustment STEP 3 Fit the primer pump bulb and cover and then secure the cover with the four cover screws E Pressure Testing Connect a Walbro tester p n 57 11 or equiva lent to the carburetor fuel inlet fitting and test the carburetor for the appropriate pop off and reseat pressures as described on page 24 Shi
119. stment should be enriched at least 5 IMPORTANT If you suspect fuel related engine damage refer to Engine Seizure in the Troubleshooting section IMPORTANT The bright stocks used in two cycle mixing oils tend to lower overall fuel octane ratings Whenever possible use only Shindaiwa Premium 2 Cycle Engine Oil blended at a ratio of 40 1 Shindaiwa Inc 1994 1 13 gt U U LL Z ik mM I gt Z O U lt U am Lu gt lt O O am E Lu m Z Lu af A lt section 13 Appendix Metric Conversions Length Volume Weight Force Power Pressure Temperature Miscellaneous 114 Tin 254mm Tin s 2 04 Cm 1 ft 30 48 cm 1 ft 304 meter 1 mile 1 609 km Cu I 16359 CC cu in 061 liter fl oz 29 574 ml fl oz 02957 liter gal 3 785 liter A t 1t 1 i k OZ 26 395 OM lb 4536 kg l in lb 1 152 kg cm in lo 112 n m ft Ib 188 kg m ft lo 1 86 n m _ i i k hp SAE 746 kw hp SAE 9861 hp DIN hp SAE 1 017 psi k 1 k psi 0689 bar psi 6 89 kpa psi 07031 kg sq cm k i F to C Temperature in F 32 x 5 9 555 1 mph 1 6 km hr 1 mpg 425 km liter Shindaiwa Inc 1994 i t 1 1 1 kh 1 1 i i i k i i i t i k i i mm
120. t Dimension A 0 083 2 1 mm 0 083 2 1 mm 0 055 1 4 mm 0 055 1 4 mm 0 083 2 1 mm 0 083 2 1 mm 0 120 3 mm 0 055 1 4 mm 0 055 1 4 mm 0 083 2 1 mm Forks must hold the purge valve against the seat 90 to purge valve Figure 3 17 Tickler lever adjustments typical Shindaiwa Inc 1994 31 SYOLAYUNEEVD U am O H Lu CC aa lt O Section 3 TK Carbu retors Reassembling E Fuel Pump TK Carburetors Assemble the fuel pump gaskets and dia continued ohragms in the reverse order of disassembly E Where multiple gaskets and diaphragms are specified assembly is correct when exterior tabs are in a stepped orientation See Figure 3 11 E Install any flapper valve springs removed during disassembly and then install and securely tighten the pump cover F Adjustment Screws Standard TK Carburetor Settings Replace the high speed and where used Model Slow Air Main Adjusting low speed mixture screws then adjust each to Screw Screw the specifications listed on the adjacent chart F T 18 Not Adjustable 1 1 2 and in the Appendix Assemble the idle speed 7 20 0 1 2 21 4 screw and spring and thread the screw T C 20 Walbro WZ mid point 1 3 8 approximately 5 turns into the carburetor T C 20 TK Not Adjustable 21 4 Oey T C LE 250 Not Adjustable 2 1 4 T C LE 25 0 1 2 2 1 2 CAUTION T C 27 0 1 2 2 1 4 Do not overtighten tapered 0 35 0 1 2 2 1 4 adjustment
121. t Outer Tube Material Diameter Wall Thickness Overall Length Shaft Type Shaft cable diameter Shaft cable length Number of Bushings CONFIGURATION Loop front handle Handlebars Grip mounted throttle Handlebar throttle Grip stop switch Engine mtd stop switch WEIGHTS Unit less accessories Ib kg Later versions of F 21 trimmers feature a one piece modular ignition system Later versions of I 20 trimmers feature a grip mounted stop switch F 18 T 18 F 20 F 21 T 20 T 230 C 230 LE 230 T 250 C 250 LE 250 STCI all models 1 1 2 2 2 1 1 1 1 1 18 kV all models 012 014 Transistorized advance all models Champion CJ 8 all models NGK BM6A all models 025 025 025 025 025 024 024 024 024 024 024 1 piece 1 piece Multi 1 piece 1 piece Sealed 1 piece T C LE 230 and T C LE 250 2 2 2 2 2 3 3 3 3 3 3 No Yes No No Yes Rubber Cushion T C LE 230 and T C LE 250 No All Models Yes All Models N A No N A No No N A No Yes Yes Shaftcase Gearcase Shaftcase Shaftcase Gearcase Gearcase w 4 bearings spiral bevel gears T C LE 230 T C LE 250 1 1 1 286 1 1 1 1 1 1 286 1 1 36 1 1 36 1 1 36 1 1 36 1 1 36 1 1 36 1 None None None None None None Aluminum Aluminum Steel Aluminum Aluminum 6061 1 6 Aircraft Alloy Aluminum Extruded and Drawn 24 mm 24 mm 20 mm 22mm 24mm 24 mm 24 mm 244mm 24mm 24mm 24mm 16mm 15mm 10mm 1 6 15mm 1 5mm 15mm 1 5mm 1 5mm 15mm 15mm 1245mm 1450mm 1372mm 1572mm 1500mm 1450mm 1450mm 1500mm
122. t gun JJ m O d gt JJ m JJ Shindaiwa Inc 1994 45 section 4 Recoil Starters Disassembling Remove the Starter Reel the Recoil continued WARNING Wear appropriate eye and face protection Use care when working with recoil springs IMPORTANT Before and during removal note both orienta tion and order of disassembly STEP 1 Carefully remove all components except the starter reel STEP 2 Carefully remove the starter reel On most models the recoil spring remains in the housing On some models including F T 18 T C 230 the recoil spring will be removed with the reel assembly STEP 3 Remove the spring from the recoil housing or reel using a needle nose pliers Figure 4 3 f the spring is to be reused it can be easily stored inside a loop of wire or small diameter jar lid such as a baby food Jar Use a needle nose pliers to remove the recoil spring Removing the NOTE Hub Failure of a starter hub is unusual It is generally not necessary to remove the hub assembly for inspection If the hub must be removed for service follow the procedure outlined below STEP 1 Lock the engine crankshaft by inserting a plastic piston stop or length of Figure 4 3 Removing the recoil spring starter cord through the spark plug hole Figure 4 4 A STEP 2 Using the appropriate socket L wrench remove the starter hub retaining nut Turn counter clockwise all models
123. t increase in vibration is common when running a unit using a 4 shoe clutch Clutch chatter at idle soeed is also common to the 4 shoe clutch and can usually be improved or eliminated by a slight adjustment to engine idle rom Figure 6 8 Tapping holes in the engine flywheel 60 Shindaiwa Inc 1994 Lu Lu T l LL Lu T O H aod O Clutches and Flywheels section 6 Troubleshooting Clutch performance and service life are directly related to operator habit E Prolonged low speed operation may cause clutch shoes to slip skid against the Worn contact clutch drum producing friction that can area quickly destroy clutch shoe facings M A slipping clutch is prone to chatter causing rapid wear to clutch springs bosses and bolt holes Figure 6 9 For optimum performance and maximum clutch life any Shindaiwa trimmer or brushcut ter should always be operated at 65 to 70 of its rated maximum rom range Bolt hole elongated Wear at spring boss CAUTION Trimmer engine speed is reduced as cutting line length increases Figure 6 9 Inspect the clutch shoe assembly Excessive line length can cause clutch shoes to slip and is the leading cause of premature clutch failure Premature clutch failure can nearly always be traced one or more of the following E Low RPM operation at or near clutch engagement speeds E idle speed set too high Recommended idle speed
124. t points Cord diameter mm Cord length mm F 18 T 18 F 20 F 21 T 20 T 230 C 230 LE 230 T 250 C 250 LE 250 18 4 1 1 18 4 1 1 19 8 1 2 214 13 21 1 1 3 22 5 1 37 2251 37 22 5 1 37 24 1 1 47 24 1 1 47 24 1 1 47 30x26 30x26 30x28 30x28 30x28 32x28 32x28 32x28 32x30 32X30 32x30 8 8 1 0 1 1 1 1 1 1 1 1 1 1 1 2 1 2 12 8 000 8 000 7 500 7 500 7 500 7 500 7 500 7 500 7 000 7 000 7 000 11 000 10 000 11 000 11 000 11 500 10 000 10000 10000 11 500 11 500 11 500 8 6 3 9 94 43 106 48 10 8 49 9 75 44 95 43 101 46 101 46 11 5 0 11 5 5 2 11 5 5 2 7 8 8 5 10 6 9 8 8 9 8 6 9 18 9 18 9 17 9 6 9 6 23 23 19 8 19 2 19 2 20 5 20 5 20 5 20 1 20 1 20 1 3 000 3 000 3 000 3 000 3 000 3 000 3 000 3 000 3 000 3 000 3 000 3 650 4 150 3 750 3 700 4 250 3 700 3 700 3 000 3 000 3 000 3 000 3 pc w pressed in crankpin F 18 I 18 F 20 F 21 1 20 3 piece 3 piece 3 piece 3 piece 3 piece 3 piece Ball bearings all models Forged 1 piece all models Caged Needle Bearing all models small End of Conrod all models Forged aluminum all models 2 2 2 2 2 2 2 2 2 2 2 Chromed open transfer ports F 18 T 18 F 20 F 21 T 20 Chrome plated Etched T C LE 230 and T C LE 250 4 to 6 pounds maximum no loss over a 3 minute test all models TK TK Walbro Walbro TK Walbro Walbro Walbro TK TK TK DPK8 amp W DPK8W WA 135 WY 24B DPVTOWIB WYL 19 WYL 19 WYL 49 DPN 10W DPN 10W DPN 10W Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 1 1 2 1 1 2 1 1 8 i 2 1 4 Replaceabl
125. tallation STEP 3 Install and tighten the hub retaining nut securely Cleaning and clean solvent and blow dry Wash all parts except the cord and handle in Inspectin eneral 9 E Inspect the starter cord for chafing wear g or deterioration Replace if noted IMPORTANT CORD REPLACEMENT CHART Cord length and diameter are critical to both Part Length Diameter D recoil spring life and overall starter perfor Model Number in mm in mm E mance If Shindaiwa pre cut replacement cord F T 18 70064 75190 29 875 759 0 130 3 O is not available refer to the cord replacement T C LE 230 70064 75190 29 875 759 0 130 3 MA chart for proper cord length and diameter F20 70030 75160 3325 845 0130 3 2 i Inspect the rope guide located in the recoil F21 70030 75160 33 25 845 0 130 3 housing for roughness or excessive wear TIC L 20 70030 75160 3325 845 0130 3 If such irregularities are noted replace the TIC 25 20000 75180 3175 806 0140 35 a housing assembly n I y C 35 20000 75180 31 75 806 0 140 3 5 m On engine inspect the hub paw and TC 27___ 20024 75160 _32 5 826 _0 140 3 5 pawl return Spring For hub related service TIC LE 250 20024 75160 325 826 0140 35 and repair procedures see Hub Removal eps ee see ee Ok E Inspect the recoil spring for bends cracks 3 40 30020 75160 31 875 810 0170 4 or corrosion Replace if noted sae p B 45 20020 75180 31 875 810 0 170 4 E Inspect the recoil housing center post and RC 45 20020 75180 31 875
126. te using an impact driver fitted with a No 2 phillips tip Figure 6 6 Remove the cover plate STEP 3 Remove the two screws securing the clutch body to the flywheel using an allen wrench STEP 4 Remove the springs and shoes from the clutch body Figure 6 7 Inspection After disassembly carefully inspect all General components Discard any assembly that shows signs of damage or excessive wear at M Clutch Shoe Contact Area M Clutch Shoe Body spring attachment point M Clutch Shoe Body bolt pivot bore E Shoulder Bolt E Spring hook ends worn or broken coils distorted E Clutch Mounting Boss 4 shoe clutch Use an impact driver to remove the cover plate screws CAUTION Always replace clutch shoes springs and shoulder bolts as a set Never replace only one component Allen wrench Assembly Lightly lubricate the shoulder bolts and the clutch mounting boss faces with a thin film of lithium based grease Reassembly is the reverse of disassembly Torque the clutch shoe shoulder bolts to the specifications listed in the Appendix lt Clutch Service Note For severe condi tions the 4 shoe clutch used on early models C 35 and B 40 can be installed on later models of C 35 B 45 and RC 45 The process involves tapping two 8mm x 1 25 mm previously untapped holes in the engine flywheel Figure 6 8 Complete procedures are described in Shindaiwa Service Bulletin PR 115 NOTE A sligh
127. tely 18 psi E he reseat value demonstrates the valve s ability to control fuel pump flow into the metering chamber and should be for Walbro carburetors no less than 10 psi for TK carburetors no less than 5 psi NOTE For accurate pressure testing the inlet needle must be slightly wet with fuel or solvent If you suspect leakage from the carburetor body itself submerge the pressurized carbu retor in clean solvent and look for bubbles NOTE When leak testing a Walbro carburetor the appearance of small bubbles around the fuel oump cover is normal Shindaiwa Inc 1994 O QO D OO CRB 26 Install pressure tester at this location Figure 3 9 Test the inlet needle assembly TK Carburetors Section 3 TK Carburetors Basic Adjustment All TK carburetors use an adjustable needle valve to regulate fuel flow at the carburetor s main jet Most TK carburetors also feature a second needle valve for adjusting low idle perfor mance When this low idle adjustment screw is opened additional air enters the carburetor on the engine side of the throttle valve which provides a potentially leaner mixture at low idle throttle settings Make initial air screw settings by rotating the idle air screw counterclockwise from the fully closed clockwise position Recommended initial settings for idle air adjustment screws vary among some engine models and are listed below Standard TK Carburetor Se
128. teps 1 5 and 8 must be replaced Although not essential an ignition analyzer can often save time and guesswork by visually displaying actual spark plug firing voltages and other performance data while an engine is operating under load Since analyzers vary in configuration and capability only basic guidelines are provided here For specifics on hookup and additional test procedures consult the owner s manual for your particular analyzer Typical Equipment A combination low voltage and kV kilovolt high voltage tester Figure 5 16 a flywheel simulator and the appropriate manual for the test equipment being used STEP 1 Test the available firing voltage between the high tension lead and ground Figure 5 17 Available firing voltage should be approximately 18 kV or more at normal cranking speed E ifthe available voltage reading is at least 18 kV or above go to Step 2 E If available voltage is low test for improper grounding or magneto air gap as in Steps 1 through 5 under Ignition Troubleshooting previous section If available firing voltage still tests low or reads 0 go to Step 2 next page Shindaiwa Inc 1994 MULTIMETER pe ACW 4 KO OFF CHECK CONT Ground to engine Figure 5 14 Testing the primary Insert probe in high tension lead MULTIMETER RT CT KO CHECK CONT Ground to engine Figure 5 15 Testing the
129. th Verify correct parts and accessories with the Illustrated Parts List IPL Check trimmer head for warpage out of round or other damage or imbalance Brushcutters A cocked or otherwise off center safety clip can prevent holders from laying flat against the blade resulting in out of balance operation Check for missing or damaged teeth and or for warped out of round or distorted blades Verify correct blade and holder using the IPL Check for accumulated debris packed around the attachment head or holders Mainshafts and Outer Tubes section 10 Diagnosing Vibration Complaints Trimmers Brushcutters Safety Clip Check Safety clip Remove Attachments off center All Units Damaged iat fia imbalanced oN blade Debris under holders Debris under holders Non approved Non d on approve anne ead Damaged Remove and imbalanced Retest head Check Powerhead Inspect shaft Replace damaged shaft and bushings Q D Damaged rotor Damaged clutch Shaft burned or discolored Is shaft bent Shindaiwa Inc 1994 93 gt V gt TI L GC W m 00 00 Lu 00 lt QO am lt Lu section 11 Gearcases General Description Figure 11 1 Disassembly except Models T C 250 94 All Shindaiwa gearcases feature hardened pinion gears supported by four ball bearings running in a cast aluminum housing with machine
130. th a frayed rope broken rewind spring or similar me chanical damage a ways verify both engine condition and operator starting procedures Variations by Recoil starting systems used on Shindaiwa Model trimmers and brushcutters can be divided into the four basic types as shown in Figure 4 1 since variations exist within types starters are not generally interchangeable between models IMPORTANT Starter component specifications and orienta tion sometimes vary widely between models and model series Before ordering or replac ing any Shindaiwa recoil starter or related components always consult the appropriate Illustrated Parts List IPL as well as appli cable service bulletins Figure 4 1 All four basic starter types are used on Shindaiwa trimmers and brushcutters Recoils are not generally interchangeable between models and both mounting systems and dimensions may vary Although some internal components may be interchangeable consult the appropriate Illustrated Parts List before attempting to substitute parts for dissimilar models 44 Shindaiwa Inc 1994 Starter housing Va Wave washer Ie ap starter Early T C 25 later models use cassette style recoil spring Friction plate C 35 B 40 B 45 BP 35 Ratchet D Ratchet Reel retaining screws T C 250 RC 45 vi Ji H mA Recoil spring NGA KA Reel Typical of T C 27 Nn dog gees Typic
131. ting when the rod is moved across the crankshaft Such damage often results from the hammer ing effects of detonation caused by operating the engine on low octane gasoline E Connecting rod small end bore Inspect for signs of excess heat including bluing or stress cracking E Connecting rod Inspect the connecting rod for signs of bending If you Suspect bending and or the piston shows signs of irregular wear replace the crankshaft assembly E Woodruff key slot and crankshaft taper Check for cracking or chipping at the woodruff key slot Also check for damage at the crankshaft taper E Threaded ends Inspect both threaded ends for stripping cross threading or other damage Replace if damaged beyond repair Shindaiwa Inc 1994 Rod Big End Rod Small End Threaded end Ss a Woodruff Key Slot Threaded end Bearing and Seal Contact Surfaces Figure 8 16 Crankshaft assembly inspection points Engine Crankcase section 8 valves ee A three piece crankshaft assembly can become twisted from a severe inertial impact such as a Sudden stoppage from a broken Run out piston or excessive use of an impact gun during routine service lt A twisted crankshaft will often reveal itself Crankshaft to a user by uneven or difficult cranking leaking crankshaft seals or loose crank Center Center shaft bearings A severely twisted crank shaft may even display a visible wobble or r
132. tion operation ea ha seizure The WZ carburetor STEP 2 Start the engine and hold the is used on early throttle at a fast idle until reaching operat model I 20 trimmers ing temperature and uses a barrel STEP 3 Set the throttle to the wide open valve throttle system The WZ carburetor is fitted with an adjustable main jet and also features a unique Pump cover a primer system assembly 7 ow instead of a conven Air filter tional choke valve assembly W O T position and then slowly turn the high speed mixture screw in then out to establish an adjustment midway between over rich and over lean O gt JJ W Cc JJ m O JJ ee ah r 1 k D Pa and cover Fuel inlet screen High speed metering assembly ee Starter wick Og The WZ carburetor features a unique airflow system It also has an adjustable high speed Metering mixture needle and an integral air cleaner diaphragm In addition both the fuel pump and metering assembly diaphragm are installed on separate sides of the carburetor body The fuel pump cover also houses the carburetors priming system During operation fuel from the metering chamber passes through the nozzle check valve and is drawn through the nozzle into the venturi air stream The nozzle check valve is also activated with the primer Fuel drawn from below the metering diaphragm causes the inlet needle to open allowing the fuel pump to refill the chamber
133. tion section 1 Brushcutters C 230 Brushcutter C 25 Brushcutter C 27 Brushcutter Shindaiwa Inc 1994 5 ai 1SCGOINN section 1 Model Designation and Indentification Brushcutters Lu m O rO ee ease A C 35 Brushcutter BP 35 Brushcutter A eee 44 bs E a SS RC 45 Brushcutter 6 Shindaiwa Inc 1994 Model Designation and Indentification section 1 Lawn Edgers ai 1SCGONN LE 230 Lawn Edger Shindaiwa Inc 1994 i H O O T 00 Lu l m O am H secion 2 Troubleshooting The 2 Stroke Cycle Engine Theory of Operation A two stroke cycle or two cycle engine produces one power stroke for every revolution of its crankshaft Intake and compression occurs during the piston s up stroke power and exhaust occurs during the down stroke Six distinct pro cesses occur during every revolution of the crankshaft Since a loss or weakness of even one of these processes will affect the other five an understanding of them will go a long way toward accu rately diagnosing problems during troubleshooting 1 Intake When the piston moves up toward the cylin der head a vacuum is created in the crank case As the piston uncovers the intake port the vacuum draws a fresh charge fuel air mixrure into the crankcase The fuel air mixture accomplishes two functions before it is moved to the combusti
134. tors CAUTION ae an Figure 3 11 Carburetor components can be a easily misplaced or damaged F through careless handling or storage Disassemble a carburetor in a well on a lighted area and keep the carburetor and e i z Slide valve all components in a small tray Refer to A oe and needle the appropriate Illustrated Parts List IPL g R D a assembly during both disassembly and reassembly A k NOTE A pressure tester such as Walbro p n 57 11 Shindaiwa p n 72174 99200 or equivalent is Idle speed o Fuel essential for the proper servicing of TK kaa carburetors Carburetor A Carburetor Removal body 0 dy STEP 1 Remove the air filter cover and filter typical it element s Meena oc STEP 2 Remove the air filter body from the assembly carburetor STEP 3 Unscrew the cap above the slide 6 valve then remove the cap and slide valve Metering ba diaphargm as an assembly ne Priming lever STEP 4 Remove the fuel line and overflow assembly tube from the carburetor body STEP 5 Remove the two screws securing the Figure 3 11 Exploded view of typical TK carburetor carburetor to the insulator block then remove the carburetor from the engine B Inlet Diaphragm Remove the priming overflow lever cover screws and cover Carefully remove the diaphragm and gasket CAUTION Never use scrapers or other metal tools to separate the cover or diaphragm C Metering Lever and Valve
135. ts crankcase a steady supply of high quality lubricant must enter the engine with the fuel mixture Refer to the Fuel and Oil Section of the Appendix for specific fuel oil information 2 Cooling Cooling any high performance engine Is a complex task To remove the heat generated from both friction and the combustion process Shindaiwa engines rely on E Lubricating Oil E Air Fuel Mixture E Cylinder Fin Design a H O O E 00 Lu l aa O am H E Flywheel Fan CAUTION Proper lubrication and cooling are essential to both the perfor mance and service life of any two cycle engne Even a partial failure in one or both of these areas can lead to engine seizure 10 Shindaiwa Inc 1994 Trou bleshooting Section 2 Troubleshooting Guide What To Check THE ENGINE DOES NOT START Possible Cause Faulty recoil starter Fluid in the crankcase Internal damage Does the engine NO crank OK Loose spark plug Excess wear on cylinder piston rings Is there good compression YES Fuel is out dated may be stale or varnished Is the fuel fresh INO and of the proper grade and mixture YES Check for clogged fuel filter and or vent Clean as required Is fuel visible and moving in the return line during priming YES The ignition switch OFF Faulty ignition ground Faulty coil and or transistor unit Is there spark at NO the spa
136. ttings Model Slow Air Main Adjusting Screw Screw F T 18 Not Adjustable 1 1 2 LT 20 0 1 2 2 1 4 T C 20 Walbro WZ mid point 1 3 8 T C 20 TK Not Adjustable 2241 4 T C LE 250 Not Adjustable 2241 4 T C LE 25 0 1 2 2 1 2 T C 27 0 1 2 2 1 4 C 35 0 1 2 2 1 4 B 40 0 3 4 2 3 4 1 4 B 45 0 1 2 2 1 2 1 4 IMPORTANT The TK idle mixture screw slow air screw controls air flow rather than fuel flow Clock wise rotation of the TK idle mixture screw reduces airflow to the engine at idle causing a richer fuel mixture to enter the engine IMPORTANT TK carburetor adjustments vary among some models and applications Before attempting any carburetor adjustment refer to the specification table above and in the Appendix The TK jet needle is secured in the slide valve by an E ring and retainer clip and is not meant to be adjusted For high altitude operation however the needle can be lowered leaning the mixture by raising the E ring Figure 3 10 Spring eee Retainer cS E ring Jet Needle F Slide Figure 3 10 The TK slide valve and jet needle must be assembled in the order shown above The standard position for the E ring is in the center most groove at the top of the jet needle For operation above 2500 feet altitude the E ring can be moved to the uppermost groove to provide a leaner fuel air mixture Shindaiwa Inc 1994 25 SYOLAYUNEEVD Section 3 TK Carbu retors Disassembling Fuelpump TK Carbure
137. un out when the flywheel is slowly rotated The preferred and most accurate method of checking for crankshaft run out requires mounting the crankshaft between centers and measuring runout with a dial indicator Figure 8 18 Figure 8 18 Measuring runout with a dial indicator A crankshaft with runout exceeding the specifications in the Appendix must be replaced mM lt O lt LL O JJ gt lt A O gt 0 LL WE Shindaiwa Gauge lf a dial indicator and centers are unavail P N 20000 96210 able runout may also be detected by holding a gauge Shindaiwa part number 20000 96210 between the assembled engine s flywheel and coil while slowly rotating the crankshaft Figure 8 19 n this test runout appears as a variation in the coil flywheel gap when the crankshaft is rotated Run out revealed by this test indicates a distorted crankshaft that must be replaced IMPORTANT The multiple piece crankshafts used on Figure 8 19 Measuring run out with a gauge Shindaiwa engines cannot be rebuilt Shindaiwa Inc 1994 T Section GO Engine Crankcase Crankcase WARNING Crankshaft G Reassembi Do not allow acetone or paint y remover to contact your skin Always wear gloves when working with solvents Always follow solvent manufacturer s directions and cautions for proper use cleanup and disposal STEP 1 Clean fasteners and mating surfaces Use acetone or a commercial gasket com pou
138. ur thumb thread the starter cord back through the notch and out through the rope guide STEP 3 Use a slip knot Figure 4 2 to prevent the starter cord from rewinding then thread on the handle and related components in the reverse order of re moval Place a stopper knot at the end of the cord Figure 4 9 remove the slip knot at the recoil housing then allow the cord to rewind Testing Spring STEP 1 While holding the recoil assembly Tension with one hand grasp the handle and pull the cord to its full length H With the cord fully extended you should still be able to rotate the reel at least 1 2 to 3 4 turn by hand O E ifthe spring appears too tight remove the starter handle and reduce spring tension at the reel by one full turn STEP 2 Replace the handle as above and POUE en ME NANE then retest for proper tension IMPORTANT A cord that fails to retract fully is usually the result of using bulk cord that has stretched or been cut too long Shindaiwa starter cord has controlled stretch and is supplied in precut lengths matched to specific models STEP 3 Install the recoil assembly on the power head Coat the recoil mounting screws with LocTite or similar adhesive and tighten securely JJ m O 2 s gt JJ m JJ 00 Assembling and To verify proper starter engagement and Testing retraction grasp the starter handle and pull the cord to its full length E If the rope pulls
139. urning an adjustable mixture screw or by replacing the main jet with one of a different size larger or smaller Shindaiwa Inc 1994 Adjust idle mixture on Walbro Models WYL WYM WY and WZ carburetors by raising or lowering the inner needle screw in the center of the carburetor s barrel valve Since the needle has no seat an initial starting or reference point can only be obtained by completely withdrawing the needle then reinstalling it to the specific number of turns as listed below Turns are counted after initial thread engagement Make subsequent adjustments in 1 8 turn increments make fine adjustments with the engine warm and running at a fast idle Adjust the needle screw to produce the highest engine rom then richen the mixture slightly by turning the mixture screw an additional 1 4 turn counterclockwise WY Initial setting 7 8 turns Models F T 18 not current WZ Initial setting 5 6 turns Model T 20 not current WYL Initial setting 12 13 turns Models T C 230 LE 230 WYM Initial setting 12 13 turns Models 300 300S Idle Speed Adjustment Screw g W S 6 Figure 3 19 Walbro fuel mixture adjustment Walbro Carburetors section 3 Dissassembling NOTE Walbro Model WYL is typical of current model Walbro Carburetors carburetors used on Shindaiwa trimmers and brushcutters Figure 3 20 Cover Walbro carburetor model WZ used on early model T 20 units are described at the en
140. ved whenever the gearcase is being refilled Failure to remove the grease collar during refilling operations can force lubricant to travel up the shaft tube and may cause the gearcase to overheat Gearcase Installation STEP 1 Lightly coat the mainshaft splines with shindaiwa lithium based gearcase lube then gently push the gearcase assembly Gress onto the shaft tube Figure 11 15 f you have difficulty engaging the spline rotate the gearcase slowly by hand during The gearcase collar must be removed when refilling the gearcase Figure 11 15 Refilling the gearcase Gearcase installation IMPORTANT The gearcase clamp assembly has a D D washer shaped washer that prevents overtightening the clamp screw The gearcase cannot be installed unless the washer Is positioned as shown in Figure 11 16 STEP 2 Install and tighten the gearcase KK GRC 06 Washer locating screw then securely tighten the Clamp screw gearcase clamp screw Install holders and attachments in the reverse of disassembly Figure 11 16 D washer installation 98 Shindaiwa Inc 1994 GearcaSes section 11 Models T C 250 Gearcase Figure 11 17 Disassembly Models T C 250 General Overall appearance and theory of operation of the T C 250 gearcase is similar to earlier models except that the T C 250 output driven shaft and gear are supplied as a single part number and cannot be disas sembled for service There
141. wa Inc 1994 87 section 10 Mainshafts and Outer Tubes Assembly Bushing Alignment If otherwise undamaged a cocked bushing can lt usually be realigned by sharply tapping the shaft continued Bushings may occasionally become mis bce a E laced Na aligned or cocked during installation THE MAINSHAFT MUST BE INSTALLED Figure 10 7 DURING THIS PROCEDURE E Check alignment by holding the outer tube vertically while inserting the mainshaft Once the shaft has passed the first two bushings it should pass freely through the remaining three E ifthe shaft catches or hangs at any bushing the bushing is misaligned and must be either realigned or replaced E Before removing and replacing the bush Figure 10 7 Re aligning a cocked bushing ing attempt realignment by using the following procedure STEP 1 Find the misaligned bushing s exact location in the shaft tube using the mainshaft as a depth guage STEP 2 Mark the misaligned bushing s location on the outside of the shaft tube with a soft lead pencil STEP 3 Install the mainshaft through all five bushings STEP 4 Realign the bushing by sharply tapping the tube around the misaligned bearing with a soft faced hammer STEP 5 Recheck alignment by removing and reinstalling the mainshaft Mainshaft Installation Apply a light coating of Shindaiwa Premium Gearcase Lube to the mainshaft and splines then install the mainshaft in the outer shaft tub
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