1
21-21H-00
PB-2100,PB-2155,PB-2200SI
2
INTRODUCTION
CONTENTS
page
We are constantly working on technical
improvement of our products. For this reason,
technical data, equipment and design are
subject to change without notice. All
specifications, illustrations and directions in
this SERVICE DATA are based on the latest
products information available at the time of
publication.
ECHO SERVICE MANUAL Ord. 403-11
(Model : PB-2100, PB-2110, ES-2100, ES-
2400) contains lots of information for servicing
this model.
1 SERVICE INFORMATION ............................. 2
1-1 Specification ............................................... 2
1-2 Technical data ............................................ 3
1-3 Torque limits ............................................... 4
1-4 Special repairing materials......................... 4
1-5 Service limits .............................................. 5
1-6 Special tools ............................................... 6
2 EMISSION ADJUSTMENT GUIDE ............... 7
2-1 General adjusting rules .............................. 7
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle....................................... 7
2-3 Adjusting carburettor.................................. 8
Reference No. 21-21H-00
I S S U E D :
2 0 0 4 11
INDEX
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
3
SERVICE INFORMATION
1-2 Technical data
Model
PB-2100
PB-2155
PB-2200SI
Engines
Idling speed
r/min
r/min
MPa (kgf/cm2) (psi)
2400 - 3200
6800 - 7700
0.83(8.4)120
Wide open throttle speed*
Compression pressure
Ignition system
Spark plug gap
mm(in)
0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1500 r/min
Secondary coil resistance
kV
16
kΩ
1.2 - 1.8
Pole shoe air gaps
Ignition timing
mm(in)
0.3 - 0.4 (0.012 - 0.016)
28
°BTDC
Carburettor
Idle adjust screw initial setting
L mixture needle initial setting
H mixture needle initial setting
Test Pressure, minimum
Metering lever height
turn in**
turn back
1 1/2
1 1/2
1 3/4
1 1/2
turn back
MPa (kgf/cm2) (psi)
1 1/2
0.05 (0.5) (7.0)
mm(in)
0.1 - 0.25 (0.004-0.010) lower than diaphragm seat
BTDC: Before top dead centre.
* With all blower pipes.
** Set idle speed screw to contact throttle plate before initial setting.
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
4
SERVICE INFORMATION
1-3 Torque limits
Descriptions
Size
M8
kgf•cm
80 - 100
25 - 35
N•m
in•lbf
70 - 85
22 - 30
30 - 45
130 - 150
22 - 35
30 - 40
60 - 95
60 - 95
30 - 45
50 - 85
26 - 40
140 - 175
140 - 175
5 - 9
Starter Pawl carrier
8 - 10
system
Starter case
M4*
M4
2.5 - 3.5
3.5 - 5.0
15 - 17
2.5 - 4.0
3.5 - 4.5
7 - 11
Ignition CDI module (Ignition coil)
35 - 50
system
Spark plug
M14
M5*
M5
150 - 170
25 - 40
Fuel
system
Carburettor insulator
Carburettor
35 - 45
70 - 110
70 - 110
35 - 50
Engine Crankcase
Cylinder
M5
M5
7 - 11
Engine mount
Muffler
M4*
3.5 - 5.0
6 - 10
M5
60 - 100
30 - 45
Others Fan case
Fan hub
M5†
M8*
M8*
M3
3.0 - 4.5
16 - 20
16 - 20
0.6 - 1.0
1.5 - 2.5
2.5 - 4.5
4.5 - 7.5
11 - 15
160 - 200
160 - 200
6 - 10
Fan
Regular bolt, nut,
and screw
M4
15 - 25
13 - 22
22 - 40
40 - 65
95 - 130
M5
25 - 45
M6
45 - 75
M8
110 - 150
*Apply thread locking sealant (See below)
†Tapping screw
1-4 Special repairing materials
Material
Thread locking sealant Starter case bolts
CDI module (Ignition coil)
Location
Remarks
Carburettor insulator screws
Engine mount
Fan hub
Loctite #222, ThreeBond 1342 or equivalent
Fan
Grease
Rewind spring
Starter center post
Lithium based grease
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
5
SERVICE INFORMATION
1-5 Service Limits
A
B
C
D
5K193
5K228
5K229
5K230
F
G
H
E
5K231
5K016
5K042
5K194
K
5K171
Description
A Cylinder bore
When plating is worn and aluminium can be seen
B Piston outer diameter
C Piston pin bore
D Piston ring groove
Min.
Max.
Max.
Max.
Min.
32.13 (1.265)
8.030 (0.3161)
1.6 (0.063)
E Piston ring side clearance
F Piston pin outer diameter
G Piston ring width
0.1 (0.004)
7.970 (0.3138)
1.45 (0.057)
0.5 (0.02)
Min.
H Piston ring end gap
K Crankshaft runout
Max.
Max.
0.05 (0.002)
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
6
SERVICE INFORMATION
1-6 Special tools
1
2
4
5
3
a = 3 mm
a = 4 mm
7
6
9
8
10
14
11
15
12
13
80
0
100
0
60
0
0
120
40
0
0
140
20
4
0
0
160
6
0
180
8
0
20
0
Key Part Number
Description
Used for:
1
2
3
4
5
6
7
8
9
897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor
363018-00310 Washer
Installing crankcase oil seal of starter side
Removing magneto rotor (flywheel)
433019-12330 Flange nut
895612-79920 L-hex wrench (3 mm)
895610-79920 L-hex wrench (4 mm)
897701-06030 Bearing wedge
897701-14732 Bearing tool
897702-30131 Piston pin tool
Removing and installing hex. socket bolt (M4)
Removing and installing hex. socket bolt (M5)
Removing and crankshaft ball bearings
Removing and installing crankcase ball bearings
Removing and installing piston pin
897705-11520
Bearing tool
Removing and installing con-rod small end needle bearing
Installing oil seals
10 897714-24330 Oil seal tool
11 897800-79931 Spark tester
12 897803-30132 Pressure tester
13 897835-16131 Pressure connector
14 900100-08008 Bolt
Checking ignition system
Testing carburettor and crankcase leakage
Checking crankcase and cylinder leakages
Removing magneto rotor (flywheel)
15
91007
Compression gauge
Measuring cylinder compression
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
7
SERVICE INFORMATION
2 EMISSION ADJUSTMENT GUIDE
2-1 General adjusting rules
Before starting the unit for adjustment, check the following items.
1. The correct spark plug must be clean and properly gapped.
2. The air filter element must be clean and properly installed.
3. The muffler exhaust port must be clear of carbon.
4. The fuel lines, tank vent and fuel filter are in good condition and clear of debris.
5. The fuel is fresh ( > 89 octane : RON) and properly mixed at 50 : 1 with “ISO L-EGD” 2 stroke oil.
6. All blower pipes are installed for proper engine loading.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
1. Turn L mixture needle clockwise until lean stop
to cut easily.
2. Using a sharp knife, give triangle cut between
the stopper wings. Also cut the H limiter cap.
NOTE : Be careful when cutting caps, otherwise
injury may result.
3. Pull the caps off with pliers.
NOTE : Do not rock back and forth when removing,
otherwise the needle may be damaged.
4. Turn H and L mixture needles clockwise until
lightly seated.
NOTE : Do not over tighten needles, otherwise
needles tip and seat damage may occur.
5. Turn L mixture needle anticlockwise 1 3/4 turns
(PB-2100), 1 1/2turns (PB-2155, PB-2200SI). Turn
H mixture needle anticlockwise 1 1/2 turns.
6. Turn idle adjust screw anticlockwise and set the
screw until the tip to just contact throttle plate. Then
turn it clockwise 1 1/2 turns.
Download from Www.Somanuals.com. All Manuals Search And Download.
PB-2100
PB-2155
PB-2200SI
8
SERVICE INFORMATION
2-3 Adjusting carburettor
1. Start engine and warm it up well for about 3 - 5
minutes with cycle of 50 seconds at WOT (Wide
Open Throttle) and 10 seconds at idling.
2. Adjust H mixture needle to obtain maximum
engine speed at WOT. And then turn H mixture
needle clockwise until the engine speed starts to
drop.
3. When the engine speed starts to drop, turn H
mixture needle anticlockwise to obtain maximum
engine speed again. And then turn H mixture needle
anticlockwise further to reduce engine speed 20 to
30 r/min (PB-2100), 10 to 20 r/min (PB-2155,
PB-2200SI) from maximum engine speed.
4. Adjust the L mixture needle to obtain maximum
idle speed.
5. Set idle speed in the range of 2,950 to 3,050 r/min
by turning idle adjust screw.
6. Turn L mixture needle anticlockwise to reduce
engine idle speed 200 to 300 r/min and set engine
idle speed in the rage of 2,650 to 2,850 r/min.
NOTE : Engine speed must be allowed to stabilize
a minimum of 20 seconds after each adjustment of
L mixture needle to assure accurate tachometer
readings.
7. After adjusting carburettor, install White limiter cap
on L mixture needle and Red limiter cap on H mixture
needle as shown.
NOTE : Before installing limiter caps, warm caps
in 90 °C hot water for smooth installation. Make it
sure to use pliers or appropriate instrument to take
warmed up cap out from the water.
8. Tap respective limiter caps to the bottoms as
shown.
9. Start engine again and make it sure engine runs
in the range of 2,400 to 3,200 r/min at idling and the
range of 6,800 to 7,700 r/min at WOT. Also make it
sure suitable acceleration.
Download from Www.Somanuals.com. All Manuals Search And Download.
|