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Workshop Manual
STRATO CHARGED ENGINE
GZ25N
Applicable Model Name:
1. Brushcutters BCZ2500S/BCZ2500SU
2. Long Reach Trimmer LRTZ2500
3. Short Reach Trimmer SRTZ2500
4. Pole Saw PSZ2500
5. Reciprocator SGCZ2500S
6. Sweeper RMSZ2500
7. Hand Held Edger HEZ2500S
8. Split Boom Trimmer : EXZ2500S
July 2000
CONTENTS
BRUSHCUTTERS BCZ2500S/BCZ2500SU
1-3
4-2
4-3
Carburetor .......................................................................................................................................... 8
Ignition System ................................................................................................................................... 8
4-4
4-5
6-3
6-4
6-5
6-6
6-7
6-8
7. CARBURETOR ............................................................................. 18
7-1
Construction ..................................................................................................................................... 18
7-2
7-3
7-4
8-2
8-3
8-4
By the stratified lead air scavenging system, the Strato-charged Engine reduces
unburned air-fuel mixture exhaust to about 1/3 of the conventional 2-stroke engine
level.
Insulator
By optimizing the combustion chamber design, ignition plug position, and ignition
timing, lean burn operation became possible.
By combining with the stratified lead air scavenging system, pollutant contained in the
exhaust was reduced and fuel consumption was reduced by 30% without reducing the
power.
400
(544)
280
(381)
171.2
(232)
139.1
(189)
54
(73) 49.5
(67)
THC + NOx
5.3
(7.2)
Current Engine
1.5
(2.0)
CO
PM
1.0
(1.3)
Tier 2 regulation
Strato-Changed Engine
Carburetor
As the catalytic converter is not applied, exhaust gas temperature increase due to the
catalytic reactive heat does not occur so that the engine heat load does not increase.
Therefore, same level of durability and reliability with the conventional engines are
assured.
A large size silencer and a muffler were employed and the noise level was reduced by
5 dB(A) compared to the conventional 2-stroke engines.
Lead Air
Burnt Gas
Burnt Gas
Air
Reed Valve
Air-Fuel Mixture
Exhaust Port
Scavenging Port
Air-Fuel Mixture
Exhaust Port
Lead Air
Crankcase
Air-Fuel Mixture
Reed Valve Assy
Air
Scavenging Port
Air-Fuel Mixture
Carburetor
Air-Fuel Mixture
Reciprocator SGCZ2500S
Spark Plug
Reed Valve
Cylinder
Carburetor
Reed Valve
Insulator
Lead Air Intake Tube
Brushcutters BCZ2500S/BCZ2500SU
Long Reach Trimmer LRTZ2500
Short Reach Trimmer SRTZ2500
Pole Saw PSZ2500
Sweeper RMSZ2500
Hand Held Edger HEZ2500S
Split Boom Trimmer : EXZ2500S
Unit
Specifications
Engine
GZ25N
Engine Type
mm (in.)
34 x 28 (1.339 x 1.102)
cc (cu.in.)
25.4 (1.6)
8.0
Mixture of 87 octane or above unleaded
gasoline and RedMax 2-cycle engine oil
(ratio 50 :1) or quality oil for air cooled
2-cycle engines (ratio 32:1).
Fuel
Carburetor
Remarks
Use JASO FC
or ISO EDG
grade 2-cycle
engine oil.
Type
Model
Walbro WYA-1B
Starting Method
Recoil starter
Ignition System
Ignition Timing
35 / 7000
Spark Plug
NGK CMR7A
Primary coil short-circuiting
Stopping Method
Cooling System
Air Cleaner
Dry Type
Counterclockwise
Clutch Type
Overall Size
mm (in.)
271 (10.67)
188 (7.40)
Width
mm (in.)
223 (8.78)
223 (8.78)
Height
mm (in.)
2489.76
2489.76
Dry Weight
kg (lbs.)
3.16.8
2.86.2
lit. (fl,oz)
0.6522.0
Operating Speed
rpm
Idling Speed
rpm
3000 200
rpm
4000 200
rpm
10000
Max Output
HP(kW) / rpm
Max Torque
kgm(in.lbs) / rpm
g/HP.h(g/kW.h)
330 (449)
(View from
PTO)
6000
10000
With Standard
Head
3. OUTLINE DRAWING
Unit : mm (in.)
Engine Cover
Carburetor
Muffler
Air Cleane
Fuel Cap
Fuel Tank
Tank Guard
122 (4.80)
223 (8.78)
Plug Cap
Fan Cover
Recoil Starter
113 (4.45)
113 (4.45)
248 (9.76)
248 (9.76)
Fan Cover
7.85
(0.31)
168 (6.61)
238 (9.36)
85 (3.35)
155 (6.10)
188 (7.40)
271 (10.67)
GZ25N for
BCZ2500S, BCZ2500SU,
LRTZ2500, SRTZ2500,
PSZ2500, RMSZ2500,
HEZ2500S and EXZ2500S.
GZ25N2 for
SGCZ2500S.
4. MAINTENANCE SPECIFICATIONS
Maintenance Item
Standard
Limit
Compression
kg/cm2 (psi)
8.7(124)
5.5(78)
Compression
Gauge
Bore
mm(in.)
34(1.339)
Cylinder
Gauge
Piston dia.
mm(in.)
33.96(1.3370)
33.975(1.3376)
33.86(1.3331)
Micrometer
1.2(0.047)
1.3(0.051)
Thickness Gauge
8(0.3150)
8.04(0.3165)
Cylinder Gauge
Clearance between
Piston & Cylinder mm(in.)
0.025(0.0010)
0.065(0.0026)
0.15(0.0059)
Micrometer /
Cylinder Gauge
0.04 (0.0016)
0.08(0.0031)
0.1(0.0039)
Thickness
Gauge
0.005T(0.00020T)
0.011L(0.00043L)
0.05L(0.0020L)
Micrometer /
Cylinder Gauge
0.1(0.0038)
0.3(0.0118
0.5(0.0197)
Thickness Gauge
1.2(0.0472)
1.1(0.0433)
Micrometer
8(0.315)
7.98(0.314)
Micrometer
11(0.433)
11.05(0.435)
Cylinder Gauge
0 0.021(0.0008)
0.045(0.0018)
Micrometer /
Cylinder Gauge
0.005(0.0002)
0.028(0.0011)
0.05(0.0020)
Micrometer /
Cylinder Gauge
0.15/100
Mandrel
Dial Gauge
12(0.4724)
11.97(0.4713)
Micrometer
12(0.472)
11.09(0.469)
Micrometer
12(0.4724)
11.97(0.4713)
Micrometer
0.07(0.028)
22
21.9
0.5(0.020)
Flutter, irregular
noise generated
12 (0.472)
12.05(0.474)
Cylinder Gauge
54(2.126)
54.6(2.150)
Vernia Calipers
Remarks
Cylinder
Piston
At right angle to
piston pin.
Piston Ring
Width mm(in.)
Measure at
cylinder skirt.
Piston Pin
Diameter mm(in.)
No stepwear is allowed
Connecting Rod
Small End Bore mm(in.)
Parallelness of Large/Small
End Bores mm(in.)
Crankshaft
mm(in.)
Eccentricity
mm(in.)
mm(in.)
22.1
Dial Gauge /
Adjust or exchange
Centre Support
Micrometer
Thickness Gauge
Clutch Drum
Bore at Bearing
Bore at Drum
mm(in.)
mm(in.)
4. MAINTENANCE SPECIFICATIONS
4-2 Carburetor
Carburetor WYA-1B
Metering Lever set. mm.(in.)
Inlet valve opening pressure. kg/cm2(p.s.i)
Inlet valve reseating pressure. kg/cm2(p.s.i)
Measuring
instrument
Limit
Standards
Maintenance Item
0.16 (0.006)
0.5 (7.1)
0.5 (7.1)
1.5 (0.059)
1.5 (21.3)
0.9 (12.8)
Remarks
Vanier
Leak Tester
Leak Tester
Maintenance Item
Measuring
instrument
Limit
Remarks
Electric parts
Spark plug air gap. mm.(in.)
Ignition coil air gap. mm.(in.)
0.6
(0.025
0.7
0.028)
0.3 (0.012)
0.7 (0.028)
Vanier
0.4 (0.016)
Ohm
Secondary side
Ohm
2300
Volt Meter
1100
Volt Meter
Unit : kg.cm(in.lbs)
Fixing torque
Screw Size
Fixing Components
Standard fix torque
Carburetor Fix Bol
Insulator Fix Bolt
Clutch
Rotor Fix Nut
Cylinder Fix Bolt
Crankcase Fix Bolt
Grass Guard Fix Bolt
Spark Plug
Muffler Fix Bolt
Engine Cover Fix Bolt
Fan Cover Fix Bolt
Ignition Coil Fix Bol
Recoil Starter Fix Bolt
Recoil Pulley
Fuel Tank Fix Bolt
Common fixing torque
Tapping Screw
Target
M5 (P=0.8)
M5 (P=0.8)
M5 (P=1.0)
M8 (P=1.0)
M5 (P=0.8)
M5 (P=0.8)
M5 (P=0.8)
M10 (P=1.0)
M5 (P=0.8)
M5 (P=0.8)
M5 (P=0.8)
M4 (P=0.7)
M5 (P=0.8)
M8 (P=1.25)
38(33)
45(39)
65(56)
130(112)
70(61)
65(56)
38(33)
110(96)
90(78)
38(33)
38(33)
33(29)
38(33)
90(78)
M5 (P=0.8)
38(33)
Tolerance
30(26)
40(35)
50(43)
100(87)
60(52)
50(43)
30(26)
100(87)
70(61)
30(26)
30(26)
25(22)
30(26)
80(69)
30(26)
TP4.3
10 (9)
7(6)
TP5.4
25(22)
20(17)
45(39)
55(48)
80(69)
150(130)
80(69)
80(69)
45(39)
120(104)
100(87)
45(39)
45(39)
40(35)
45(39)
100(87)
45(39)
15(13)
30(26)
Engine Block:
MATERIAL TO BE APPLIED
AREA
Grease
Grease
Clutch:
AREA
Sliding portion
of screw.
MATERIAL TO BE APPLIED
Grease
MATERIAL TO BE APPLIED
Grease
2-cycle oil
2-cycle oil
2-cycle oil
2-cycle oil
5. SPECIAL TOOLS
Part name
Puller Assy
Part No.
External appearance
Usage
2890-96100
To remove rotor.
Piston Stopper
4810-96220
Rod Assy
1101-96220
3350-96240
Hex Wrench
3304-97611
Puller
4500-96100
5500-96110
Drum Remover
5500-96120
5500-96130
10
5500-96140
6. SERVICE GUIDE
Assembly precautions
from each part. This is to prevent dirt from becoming attached to the important locations.
Tool usage
Use the indicated tools correctly to avoid damaging parts.
Note:
Do not use gasoline or oil to clean vibration
damping rubber.
Note:
10
6. SERVICE GUIDE
Stopper
Grease
Clutch Shoe
Caution:
Care for orientation of the wave washers and clutch
shoe.
Arrow marks on the
upper surface
Clutch Shoe
Wave
Washer
Remove the rotor using the puller assy (289096100). Apply 8mm puller bolts.
17mm Hex.
Rotor
Puller bolts
Puller
11
6. SERVICE GUIDE
Pulley
Puller
Note:
Pulley screw is right turn screw.
Wrench
0.4mm(0.012
0.016in.)
Gauge
Ignition coil
16mm
Important:
Fixing the spark plug using other tools than the
custom plug wrench may apply over torque and end
up with damages of threads on the cylinder.
12
6. SERVICE GUIDE
Coil
Black
Clip
Caution:
Check that the plug cap is not deteriorated, stiffened,
nor has cracks.
Also check that there is no play after fitting the cap.
Rod Assy
Piston
Plastic Hammer
Caution:
Hard hammering may damage the big end of the
connecting rod.
13
6. SERVICE GUIDE
Allow mark
Exhaust side
Piston
Circlip
End Gap
Cylinder Gasket
Caution:
An oppositely set gasket will touch with the insulator,
and makes a gap between the muffler. Therefore, the
cooling air to the cylinder is leaked toward the tank
and the cooling performance is reduced.
Arrow Mark
14
6. SERVICE GUIDE
Muffler side
Notch
Cylinder Plate
Insulator Gasket
15
6. SERVICE GUIDE
Important:
Check the gap between the valve case and the reed
Reed Valve
valve.
Replace with new valve if the gap is larger than
0.2mm (0.008in.), or the valve is distorted.
Snap Ring
Pliers
Housing Assy
Snap Ring
Clutch Drum
16
6. SERVICE GUIDE
Hammer
Drum Remover
Clutch Drum
Snap Ring
Guide
Caution:
Make sure to replace the snap ring if it is deformed.
Snap Ring
Clutch Drum
2) Applying grease
Molybdenum Grease
17
7. CARBURETOR
STRATO
STRATO CHARGED
CHARGEDENGINE
ENGINEGZ25N
7-1 Construction
The Strato-charged Engine is applied with a custom designed carburetor employing diaphragm rotary
valves and 2 venturies, one for the lead air and the other for the air-fuel mixture.
Lead Air
To Reed Valve
Insulator
Air-fuel Mixture
Throttle Valve
A : Lead Air Port
Carburetor
unit: mm
18.1
Idling
Lead air : Close
Venturi bore
Mixture : Start to open
8
Air-fuel Mixture
block
Mid speed
Lead air : Start to open
13.0
Rotary Valve
18
High speed
Lead air : Full open
7. CARBURETOR
7-3 Specifications
Item
Unit
Specifications
Product Name
Engine Type
GZ25N
Carburetor
Type Name
WYA-1B
Part Number
4810-81001
Carburetor Specification
Main Jet
#38.5
mm (in.)
Venturi Bore
mm (in.)
Choke Bore
mm (in.)
13.2 (0.5210)
kg/cm (psi)
kg/cm (psi)
1.0
2.0 (14.2
28.4)
0.4
1.4 (5.69
19.91)
Speed
Idling
rpm
2800
3200
Clutch engaging
rpm
3800
4200
Stall
rpm
5650
6150
Operating Speed
rpm
rpm
6000
10000
10000
19
7. CARBURETOR
Adjust Screw
Adjust Nut
Swivel
Washer
Adjustment Screw
Clip
Throttle Valve
Carburetor Body
O-ring
O-ring
Gasket
Main Jet(38.5)
Pump Diaphragm
Body
Valve
Pin
Screw
Diaphragm
Purge body
Priming Pump
Pump Cove
Screw
Plastic Pipe
Main Check Valve
20
8. TROUBLE SHOOTING
Cause
Countermeasure
Magneto
Switch
Cleaning
Exchange
Exchange
Exchange
Exchange or repair
1.Switch is OFF
ON the switch
2. Switch failure
Exchange
Repair
Adjust carburetor
3.Overflow
5.Faulty fuel
Exchange
No fuel supply
Cleaning
2.Clogged carburetor
Cleaning
Cause
Countermeasure
1.Switch is OFF
ON the switch
Exchange
Exchange
6. Engine seizure
Overhaul
1.Lack of fuel
Supply fuel
Cleaning
21
8. TROUBLE SHOOTING
Cause
Countermeasure
1.Lean fuel
Adjust carburetor
Cleaning
3.Inproper fuel
Switch
1.Faulty switch
Exchange
2.Cable failure
Repair
Cause
Overheating
Others
Countermeasure
Secure connection
Change gasket or tightening
screws
3 Water in fuel
Cleaning
Exchange
Cleaning or exchange
components
Cleaning or exchange
Adjust carburetor
Cleaning
Cleaning
2. Over loading
Reduce load
Note : Hatched columns above are potential failures unique to the stratified scavenging engine.
22
23