Bolens BL100, BL150 manual 5

MAINTENANCE AND REPAIR INSTRUCTIONS

MAINTENANCE AND REPAIR INSTRUCTIONS

Always use original equipment manufacturer 0.080 in. (2.03 mm) replacement line. Line other than the specified may make the engine overheat or fail.

There are two methods to replace the trimming line:

•Wind the inner reel with new line

•Install a prewound inner reel

Winding the Existing Inner Reel

1.Hold the outer spool with one hand and unscrew the Bump Knob™ counterclockwise (Fig. 12). Inspect the bolt inside the Bump Knob to make sure it moves freely. Replace the Bump Knob if damaged.

2.Remove the inner reel from the outer spool (Fig. 13).

3.Remove spring from the inner reel (Fig. 13).

4.Use a clean cloth to clean the the inner reel, spring, shaft, and inner surface of the outer spool.

5.Check the indexing teeth on the inner reel and outer spool for wear (Fig. 14). If necessary, remove burrs or replace the reel and spool.

NOTE: SplitLine™ can only be used with the inner reel with the slotted holes. Single line can be used on either type of inner reel. Use Figure 15 to identify the inner reel you have.

NOTE: Always use the correct line length when installing trimming line on the unit. The line may not release properly if the line is too long.

Bump Knob™

Bolt

Fig. 12

Outer Spool

Spring

Inner Reel

Fig. 13

Indexing Teeth

3.	Wash the filter in detergent and water (Fig. 23). Rinse the	Blue Choke
	filter thoroughly. Squeeze out excess water. Allow it to dry	Lever
	completely.	Position 2

4. Apply enough clean SAE 30 oil to lightly coat the filter (Fig. 24).

5.	Squeeze the filter to spread and remove excess oil (Fig. 25).
6.	Replace the air filter inside the air filter/muffler cover (Fig. 22). Screws	Screws
NOTE:	Operating the unit without the air filter and air
	filter/muffler cover assembly will VOID the warranty.
Reinstalling the Air Filter/Muffler Cover
1.	Place the air filter/muffler cover over the back of the	Fig. 21
	carburetor and muffler. Align the screw holes.

2. Insert the four (4) screws into the holes in the air filter/muffler cover (Fig. 21) and tighten. Do not over tighten.

SPARK ARRESTOR MAINTENANCE

1.Remove air filter/muffler cover. Refer to Removing the Air

Filter/Muffler Cover.

2.	Locate the muffler, but do not remove it. Find the screw on	Air Filter
	the bottom of the muffler (Fig. 26). Remove the screw using
	either a torx #20 or flat blade screwdriver.	Inside Muffler Cover
3.	Carefully pry up the left side spark arrestor hood. Two tabs	Fig. 22
	act as hinges on the right side of the hood. Flip open the
	spark arrestor hood like a door and then pull its tabs out of
	the muffler slots.

4. Using a small flat blade screwdriver, carefully pry the spark

Single Line Installation

Go To Step 8 for SplitLine™ Installation

6.	Take approximately 20 feet (6 m) of new trimming line, loop
	it into two equal lengths. Insert each end of the line through
	one of the two holes in the inner reel (Fig. 16). Pull the line
	through the inner reel so that the loop is as small as	Fig. 14
	possible.

arrestor screen out from the inside of the spark arrestor hood.

5. Clean the spark arrestor screen with a wire brush. Replace it if it is damaged, or if you are unable to clean it thoroughly.

6.Reinstall the spark arrestor screen snugly back into the spark arrestor hood.

7.	Reinstall the two hood tabs into the two muffler slots and	Fig. 23
	flip the spark arrestor hood closed.

7.Wind the lines in tight even layers, onto the reel (Fig. 17). Wind the line in the direction indicated on the inner reel. Place your index finger between the two lines to stop the lines from overlapping. Do not overlap the ends of the line. Proceed to step 11.

SplitLine™ Installation

8.Take approximately 10 feet (3 m) of new trimming line. Insert one end of the line through one of the two holes in the inner reel (Fig. 18). Pull the line through the inner reel until only about 4 inches is left out.

9.Insert the end of the line into the open hole in the inner reel and pull the line tight to make the loop as small as possible (Fig. 18).

10.Before winding, split the line back about 6 inches.

11.Wind the line in tight even layers in the direction indicated on the inner reel.

NOTE: Failure to wind the line in the direction indicated will cause the cutting attachment to operate incorrectly.

12.Insert the ends of the line into the two holding slots (Fig. 19).

13.Insert the ends of the line through the eyelets in the outer spool and place inner reel with spring inside the outer spool (Fig. 20). Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the holding slots in the reel.

For Use with	For Use with
Single Line ONLY	Splitline™ or
	Single Line ONLY

Slotted

Holes

Fig. 15

Loop

Fig. 16

8. Replace the screw you removed in Step 2 and tighten it securely.

9. Reinstall the air filter/muffler cover.

WARNING: If the spark arrestor hood and spark arrestor screen are not tightened securely, they could fall off causing damage to the unit and possible serious personal injury.

CARBURETOR ADJUSTMENT
The idle speed of the engine is adjustable through the air		Fig. 24
filter/muffler cover (Fig. 27).
NOTE:	Careless adjustments can seriously damage your
	unit. An authorized service dealer should make
	carburetor adjustments.
Check Fuel Mixture
Old and/or improperly mixed fuel is usually the reason for improper unit
performance. Drain and refill the tank with fresh, properly-mixed fuel prior
to making any adjustments. Refer to Oil and Fuel Information.
Clean Air Filter
The condition of the air filter is important to the operation of the unit. A dirty		Fig. 25
air filter will restrict air flow and change the air/fuel mixture. This is often
mistaken for an out of adjustment carburetor. Check the condition of the air		Slots	Engine
filter before adjusting the idle speed screw. Refer to Air Filter Maintenance.

NOTE: The spring must be assembled on the inner reel before reassembling the cutting attachment.

14.Hold the inner reel in place and install the bump knob by turning clockwise. Tighten securely.

INSTALLING A PREWOUND REEL

1.Hold the outer spool with one hand and unscrew the bump knob counterclockwise (Fig. 12). Inspect the bolt inside the bump knob to make sure it moves freely. Replace the bump knob if damaged.

2.Remove the old inner reel from the outer spool (Fig. 13).

3.Remove the spring from the old inner reel (Fig. 13).

4.Place the spring in the new inner reel.

NOTE: The spring must be assembled on the inner reel before reassembling the cutting attachment.

5.Insert the ends of the line through the eyelets in the outer spool (Fig. 20).

6.Place the new inner reel inside the outer spool. Push the inner reel and outer spool together. While holding the inner reel and outer spool, grasp the ends and pull firmly to release the line from the holding slots in the spool.

7.Hold the inner reel in place and install the bump knob by turning clockwise. Tighten securely.

AIR FILTER MAINTENANCE

Removing the Air Filter/Muffler Cover

WARNING: To avoid serious personal injury, always turn your unit off and allow it to cool before you clean or service it.

1.Place the blue choke lever in Position 2 (Fig. 21).

NOTE: The blue choke lever must be in Position 2 to remove the air filter/ muffler cover.

2.Remove the four (4) screws securing the air filter/muffler cover (Fig. 21). Use a T-20 Torx bit screwdriver.

3.Pull the cover from the engine. Do not force.

Cleaning the Air Filter

Clean and re-oil the air filter every 10 hours of operation. It is an important item to maintain. Failure to maintain your air filter properly can result in poor performance or can cause permanent damage to your engine.

1.Remove air filter/muffler cover. Refer to Removing the Air Filter/Muffler Cover.

Fig. 17

Loop

Fig. 18

Index Teeth

Fig. 19

Eyelets

Spring

Fig. 20

		Spark		Muffler
Adjust Idle Speed Screw		Arrestor
		Hood
	WARNING: The cutting attachment will spin
	during idle speed adjustments. Wear protective
	clothing and observe all safety instructions to
	prevent serious personal injury.
If, after checking the fuel mixture and cleaning the air filter, the		Screw		Spark Arrestor
engine still will not idle, adjust the idle speed screw as follows:			Tabs	Screen
1.	Start the engine and let it run at a high idle for a minute to			Fig. 26
				Idle Speed Screw
	warm up. Refer to Starting/Stopping Instructions.
2.	Release the throttle trigger and let the engine idle. If the engine
	stops, insert a small phillips screwdriver into the hole in the air
	filter/muffler cover (Fig. 27). Turn the idle speed screw in,
	clockwise, 1/8 of a turn at a time (as needed) until the engine
	idles smoothly.
3.	If the engine appears to be idling too fast, turn the idle speed
	screw counterclockwise 1/8 of a turn at a time (as needed),
	to reduce idle speed.
Checking the fuel mixture, cleaning the air filter, and adjusting the
idle speed should solve most engine problems. If not and all of the				Fig. 27
following are true:

• the engine will not idle

• the engine hesitates or stalls on acceleration

•there is a loss of engine power

Have the carburetor adjusted by an authorized service dealer.	0.025 in.
REPLACING THE SPARK PLUG	(0.635 mm)

WARNING: To prevent serious personal injury, make sure the cutting attachment has stopped rotating after you turn it off and before you set it down.

Fig. 28

Use a Champion RDJ7Y spark plug, or equivalent. The correct air gap is 0.025 inch (0.635 mm). Remove the plug after every 25 hours of operation and check its condition.

1.Stop the engine and allow it to cool. Grasp the plug wire firmly and pull it from the spark plug.

2.Clean around the spark plug. Remove the spark plug from the cylinder head by turning a 5/8-inch socket counterclockwise.

WARNING: Do not sand blast, scrape or clean electrodes. Grit in the engine could damage the cylinder.

2.Turn cover over and look inside to locate the air filter. Remove the air filter from inside the air filter/muffler cover (Fig. 22).

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