Workshop Manual
Workshop Manual
Workshop Manual
Chainsaw
GS35 GS350 MT350 MT3500
Suggested tools
I.
II.
III.
I.
II.
p/n 3055125
III.
p/n 001000785
p/n 001000392A
Index
1) Performance
a)
Compression test
b)
Cylinder and piston inspection
c)
Cylinder and piston assembly
d)
Cooling system cleaning
e)
Muffler inspection
2) Fuel system
a)
Fuel and fuel filter inspection
b)
Fuel system test
c)
Tank breather inspection
d)
Engine seal test
e)
Manifold inspection
3) Ignition system
a)
Starter housing inspection
b)
Spark plug inspection
c)
Spark test
d)
Flywheel-coil air gap inspection
e)
Flywheel key inspection
4)
5)
Tuning
a)
Air filters inspection
b)
Needle valve inspection
c)
Carburetor inspection
d)
Suggested tools for carburetion setting
e)
Carburetion tuning
6)
Tightening torques
7)
Trouble shooting
a)
The engine does not start
b)
Low performance
c)
Additional problems
1) Rendimento
a)
b)
c)
d)
e)
Compression test
Cylinder and piston inspection
Cylinder and piston assembly
Cooling system cleaning
Muffler inspection
a)
Compression test
Apply the Emak compression
tester
(I) on cylinder. Pull
energetically the rope 10 times
Verify that the compression
value in not less than 7,5 bar
110 psi
If the value in higher than
7,5 bar 110 psi, start
inspection d), if lower, carry on
with inspection b)
p/n 001000392A
b)
c)
Warning:
The arrow on the top of the cylinder points towards
the exhaust port.
d)
Important:
Clean weekly the cooling system, more
frequently in heavy duty work conditions
Use Loctite 243 to tighten plastic component
Tightening toque cover-basement
0,4 kgm (34,72 in lb) + Loctite 243
Tightening torque
Cover
0,4 kgm (34,72 in lb)
+ Loctite 243
e)
Muffler inspection
Catalytic muffler
Verify the conditions of the muffler (dirt / oily)
change if necessary
Non-catalytic muffler
If the muffler is blocked or damaged, clean or replace it
Back to index
2) Fuel system
a)
b)
c)
d)
e)
a)
b)
Go to
Carburetor inspection
Sintered
internal
filter
c)
p/n 1043900
d)
III
p/n 001000018
IV
II
n3 screws M5x25
p/n 094500388A
Warning:
During the seal test use
only a light torque of
0,4 Kgm (35 in lb)
Fit the pressure gauge (V) to the inlet and apply 0.5 bar. The pressure should not descend
p/n 1043900
e)
Manifold inspection
Check the manifolds for wear. Verify that the manifolds rubber is not deteriorated or hardened and check
that there are no cuts or holes. Replace if necessary
Warning!
Make sure the impulse path is
correctly inserted into the
cylinder hole.
Back to index
3) Ignition system
a)
b)
c)
d)
e)
a)
Counterclockwise
turn to release
the spring
Clockwise turn
to wind the
spring
b)
c)
RCJ-7Y
(0,5 0,7 mm)
Spark test
Fit the tester (I) between spark plug and spark
plug cap. Pull the rope and verify the current
Replace the spark plug if necessary. Verify that the
spark plug thermal grade and type (resistive R)
are correct
Check that the spark plug pipe is correctly
connected, cables are not damaged and coil works
properly
cod. 001000515R
d)
e)
II
p/n 001000004
III
p/n 001000782
Back to index
a)
Warning!
Make sure the O-ring (I) is
seated before inserting the tube
b)
c)
d)
II
p/n 3055133
p/n 001000684
Warning! Make
sure the spacer
washer is fitted (I)
Remove the oil pump. Check the pump and worm gear.
Inspect the supply hose and filter, clean.
Warning!
Use a liquid gasket to seal in the
hose to the saw body
e)
p/n 3055133
Photo 1
Photo 2
f)
g)
Keep
clean
O
SS
A
R
Back to index
5) Tuning
a)
b)
c)
d)
e)
a)
Tightening torque
Support air filter-carburetor
0,4 Kgm (34,72 in lb)
+ Loctite 243
b)
c)
Carburetor inspection
Check and clean all components (diaphragm,
needle, filter). Use the repair kit to replace worn
components. If the carburetor is oxidized, replace
it
Needle
OK
REPLACE
GS35 GS350 MT350 MT3500 chainsaws
d)
p/n 3055130
e)
Carburetor tuning
Correct tuning of the EURO 1 (direttiva 97/68/CE + 2002/88/CE) and EURO 2 (direttiva 97/68/CE + 2002/88/CE
+ 2004/26/CE).
The jets have the following factory registration: L = 1+3/81/4
H=11/4
When, following a repair or engine overhaul, you are obliged to re-tune the carburetor to its original setting
Start the unit and warm up for 60 seconds. If the engine stop, readjust T screw
Close the L jet until the maximum number of rpm is reached (stop rotating the jet before the rpms drop or
the unit stalls);
Adjust the T screw until the unit reaches an idle rpm between: 3700 and 4200 RPM
Open the jet L until the rpm go from 3700/4200 to 2800/3100 RPM
Maximum adjustment (H)
5.
Adjustment of the jet H for wide open throttle operation whit bar (standard 16 - 41 cm) and chain:
10600 RPM with the new motor and 12100 RMP with run-in engine
Back to index
Tightening torques
(kgm) (in lb) / lubrication
* = Loctite 243
G = Grease
O = Oil
6) Tightening torques
2 177,0
0,4 - 34,72 *
0,4 - 34,72 *
0,25 22,13 *
1,9 - 168,2 *
0,6 - 52,08 *
0,25 22,13 *
0,6 - 52,08 *
0,25 22,13 *
0,2 17,7 *
Tightening torques
(kgm) (in lb) / lubrication
* = Loctite 243
G = Grease
O = Oil
0,4 - 34,72 *
0,35
30,98 *
0,7 61,96 *
0,35
30,98 *
0,7 61,96 *
0,04 3,54
0,4 - 34,72 *
0,35
30,98 *
0,4 34,72 *
Tightening torques
(kgm) (in lb) / lubrication
0,35 30,98 *
* = Loctite 243
G = Grease
O = Oil
Tightening torque
(kgm) (in lb) / lubrication
* = Loctite 243
G = Grease
O = Oil
0,5 44,25 *
0,45 - 39,83 *
1,5 132,76
2 - 177,0 *
G
0,25 - 22,13 *
Back to index
Causes
Remedies
Go to
Section 3
2. There is no
compression
3. No spark
Section 1
Section 1
Section 1
Section 3
Section 3
Section 2
Section 2
Section 5
Section 5
Section 5
Section 5
Section 2
1. Engine
overheating
2. Engine
performance is
not stable
Causes
Remedies
Go to
Section 5
Section 1
Section 2
Section 1
Section 1
Section 5
Section 3
Section 5
2.d Seizure
Section 1
Section 5
Causes
Remedies
Go to
Section 4
Section 4
Section 4
Owners
manual
Owners
manual
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