11-50A-04 RM-520ES, BP510S 1

SERVICE DATA
TRIMMER/BRUSHCUTTER
ECHO: RM-520ES
shindaiwa: BP510S
(Serial number : 37000001 and after)
(Serial number : 38000001 and after)

INTRODUCTION CONTENTS
page
We are constantly working on technical im- 1 SERVICE INFORMATION............................... 2
provement of our products. For this reason, 1-1 Specifications.............................................. 2
technical data, equipment and design are 1-2 Technical data.............................................. 3
subject to change without notice. All speci- 1-3 Torque limits................................................ 4
fications and directions in this SERVICE 1-4 Special repairing materials.......................... 4
DATA are based on the latest product infor- 1-5 Service limits............................................... 5
mation available at the time of publication. 1-6 Special tools................................................ 6

2 SERVICE HINT............................................... 7
2-1 Removing gear case assembly
from clutch case............................................ 8
2-2 Replacing gears and ball bearings................. 9

Reference No. 11-50A-04

REVISED: 202007
ISSUED: 201601

Copyright(C)2018 YAMABIKO Corporation All rights reserved.

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RM-520ES
SERVICE INFORMATION BP510S

1 SERVICE INFORMATION
1-1 Specifications
Dimensions*1 Length mm (in) 2824 (111.2)
Width mm (in) 449 (17.7)
Height mm (in) 564 (22.2)
2
Dry weight* kg (lb) 11.9 (26.2)
Engine Type YAMABIKO, air-cooled, two-stroke, single cylinder
Rotation Counterclockwise as viewed from the output end
Displacement cm3 (in3) 50.2 (3.06)
Bore mm (in) 44.0 (1.73)
Stroke mm (in) 33.0 (1.30)
Compression ratio 7.1
Carburetor Type Diaphragm, horizontal-draft
Model WALBRO WT-1096
Venturi size - Throttle bore mm (in) 13.5 - 15.85 (0.53 - 0.62)
Ignition Type CDI (Capacitor discharge ignition) system, Digital magneto
Spark plug NGK BPMR8Y
Exhaust Muffler type Spark arrester muffler
Starter Type ES-start (effortless) / S Start (Soft)
Rope diameter x length mm (in) 3.8 x 800 (0.15 x 31.5)
3
Fuel* Type*4 Mixed two-stroke fuel
Mixture ratio 50 : 1 (2%)
Gasoline Minimum 89 octane
Two-stroke engine oil ISO-L-EGD (ISO/CD13738), JASO FC/FD
Full tank capacity: 1.07 (36.2)
Tank capacity L (U.S.fl.oz.)
Usable capacity: 1.06 (35.8)
Clutch Type Centrifugal, 2-shoe pivot
Handle Type Front : Crescent loop with cushion grip
Rear : Integrated control grip with cushion
Angle Reduction ratio 1
transmission Gear tooth Spiral bevel gear
Lubrication Urea based grease
Drive shaft Type Solid type with serration (10-tooth)
Diameter - Length mm (in) 8.0 - 1140 (0.31 - 44.88)
Housing OD - ID mm (in) 25.0 - 22.6 (0.98 - 0.89)
Length mm (in) 330 (12.99)
Gear case Reduction ratio 1.33
Gear tooth Spiral bevel gear
Lubrication Lithium based grease
Cutter Type Nylon line cutter Z5
Arbor diameter for blade mm (in) 25.4 (1.0)
Fastener type, size mm Left-hand thread nut, M10 x 1.25 pitch
Cutting rotation Counterclockwise as viewed from top
OD: Outer diameter. ID: Inner diameter.
*1 Without cutting attachment *2 Without cutting attachment and Shield *3 Refer to Operator’s manual
*4 Premixed alkylate fuel for 2-stroke can be used
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RM-520ES
BP510S SERVICE INFORMATION

1-2 Technical data

Engine
Compression pressure MPa (kgf/cm2) (psi) 1.0 (10.2) (145)
Clutch engagement speed r/min 3,650
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Spark test Tester gap w/ spark plug mm(in) 4.0 (0.16)
Tester gap w/o spark plug mm(in) 6.0 (0.24)
Secondary coil resistance Ω 980 - 1,020
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing at 3,000 r/min °BTDC 14
at 8,000 r/min °BTDC 27
at 10,000 r/min °BTDC 29
Carburetor
Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 1.65 (0.06) lower than diaphragm seat
Tool to adjust mixture needles D-shaped (L) P/N X645-000031
(Carb. adjustment tool P/N Y089-000094)
Carburetor adjustment
Nylon line cutter Z5
Cutting head preparation 1
Line length* 220 mm
1) Initial setting H mixture needle turn out 2 7/8
L mixture needle turn out 1 7/8
2
Throttle adjust screw turn in* 2 1/4
Engine warm-up Idle - WOT : Total sec. 10 - 50 : 180
2) Find idle maximum speed Adjust L mixture needle to maximum idle speed*3
3) Set idle maximum speed w/ TAS r/min 3,600
4) Set idle speed
r/min 2,800
by turning L mixture needle CCW
5) Find WOT maximum speed r/min Adjust H mixture needle to maximum WOT speed
6) WOT setting Turn H mixture needle CCW
r/min to decrease WOT speed by : 120
7) Verify final engine speed with standard equipment Idle: 2,400 - 3,300
r/min WOT: 10,400 - 11,400
8) Verify clutch engagement speed Confirm clutch engagement speed.
If it is less than 1.25 times the idle speed, adjust
the idle speed by turning TAS CCW.

BTDC: Before top dead center. WOT: Wide open throttle CCW: Counterclockwise TAS: Throttle adjust screw

*1 From eyelet on nylon head

*2 Set Throttle adjust screw to the point that its tip just contacts throttle plate before initial setting.
*3 If clutch engages during adjustment process 2), decrease engine speed by turning TAS CCW until clutch
disengages and then redo 2).
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RM-520ES
SERVICE INFORMATION BP510S

1-3 Torque limits

Descriptions Size N•m kgf•cm in•lbf
Starter Starter pawl M5 6-9 60 - 90 50 - 80
system Starter case M5 3 - 4.5 30 - 45 26 - 40
Ignition Magneto rotor (Flywheel) M8 20 - 24 200 - 240 175 - 210
system Ignition coil M5 5-7 50 - 70 45 - 60
Spark plug M 14 13 - 17 130 - 170 115 - 150
Fan cover M 5* 3 - 4.5 30 - 45 26 - 40
Fuel Carburetor M5 4 - 5.5 40 - 55 35 - 50
system Intake bellows M 5* 3-5 30 - 50 26 - 45
Intake insulator M 5* 6-8 60 - 80 53 - 70
Insulator plate M 5* 3 - 4.5 30 - 45 26 - 40
Fuel tank bracket M5 5-7 50 - 70 45 - 60
Fuel tank M5 5-7 50 - 70 45 - 60
Clutch Clutch shoe M8 20 - 23 200 - 230 175 - 200
Clutch hub M10 20 - 23 200 - 230 175 - 200
Engine Crankcase M 5** 7 - 11 70 - 110 60 - 95
Cylinder M 5** 7 - 11 70 - 110 60 - 95
Cylinder cover M 5* 2-3 20 - 30 17 - 26
Stand M 5* 3 - 4.5 30 - 45 26 - 40
Muffler M6 10 - 14 100 - 140 90 - 125
Muffler cover M 5* 3 - 4.5 30 - 45 26 - 40
Muffler stay M5 6-9 60 - 90 50 - 80
Others Blade fastening nut LM 10 28 - 32 280 - 320 245 - 280
Regular bolt, nut and screw M3 0.6 - 1 6 - 10 5-9
M4 1.5 - 2.5 15 - 25 13 - 22
M5 3 - 4.5 30 - 45 26 - 40
M6 4.5 - 7.5 45 - 75 40 - 65
M8 11 - 15 110 - 150 95 - 130
M 10 21 - 30 210 - 300 180 - 260

LM: Left hand thread

* Apply thread locking sealant. (See below)
** The torque differences among four bolts should not exceed 20 kgf• cm (2N•m, 17in•lbf) on one cylinder or
crankcase.

1-4 Special repairing materials

Material Location Remarks
Grease Flexible shaft* PYRONOC (Urea based grease)
Angle transmission P/N: X695-000070
Gear case
Rewind spring EPNOC AP2 (Lithium based grease)
Starter center post P/N X695-000060
Drive shaft
Oil Oil seal inner lips Two-stroke engine oil or engine oil (SAE#30)
Thread locking sealant Muffler cover Loctite #242, ThreeBond #1324 or equivalent
* Evenly grease all the surface of the flexible shaft approximately 10 mL in every 18 hours.
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RM-520ES
BP510S SERVICE INFORMATION

1-5 Service limits

A B C D

5K245 5K222 5K223 5K224

E F G H

5K225 5K016 5K042 5K246

K L M

5K219 5K220 5K189

Description mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 43. 92 (1.571)
C Piston pin bore Max. 11. 035 (0.4344)
D Piston ring groove Max. 1. 6 (0.063)
E Piston ring side clearance Max. 0. 1 (0.004)
F Piston pin outer diameter Min. 10. 98 (0.4323)
G Piston ring width Min. 1. 45 (0.057)
H Piston ring end gap Max. 0. 5 (0.02)
K Con-rod small end bore Max. 15. 025 (0.5915)
L Crankshaft runout Max. 0. 02 (0.001)
M Clutch drum bore Max. 79. 5 (3.13)
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RM-520ES
SERVICE INFORMATION BP510S

1-6 Special tools

1 2 3 4 5

e
0 0 m ug
9 1 5m a
3 G
6

/N = . p
4 Ga
01 ir

4
A
n
tio
Made in Germany
T27x200

ni
8 6 9 7 4 5

#.
Ig

P
0 1 0 5 5 7
4

7 8 9 10 12 13

65

1.
1.

35
4
0.

1.
5
4 3
11 14
5

2
6

7 0

15 16 17 18 19

20 21 23 24 25

22

Key Part Number Description Reference

1 X602-000340 Torx wrench (T27) Removing and installing torx bolt
2 897802-33330 Tachometer PET-1000R Measuring engine speed to adjust carburetor
3 897800-79931 Spark tester Checking ignition system
4 91004 Module air gap gauge Adjusting pole shoe air gaps
5 V265-000200 Flange nut Removing crankshaft from crankcase (clutch side)
6 900100-08008 Bolt Removing crankshaft from crankcase (clutch side)
7 Y089-000111 Puller Removing magneto rotor
8 Y089-000094 Carburetor adjustment tool Adjusting carburetor
9 500-500 Welch plug tool (Walbro) Removing and installing welch plug
10 897563-19830 Metering lever gauge Measuring metering lever height on carburetor
11 X644-000020 Piston stopper Locking crankshaft rotation
12 91041 Pressure rubber plug Plugging exhaust port to test crankcase / cylinder leakages
13 897826-16131 Pressure rubber plug Plugging intake port to test crankcase / cylinder leakages
14 897827-16131 Pressure plate Plugging intake port to test crankcase / cylinder leakages
15 91149 Pressure / vacuum tester Testing crankcase and cylinder leakages
16 897803-30133 Pressure tester Testing carburetor and crankcase leakages
17 91037 Compression gauge Measuring cylinder compression
18 897701-14732 Bearing tool Removing and installing ball bearings on crankcase
19 897701-02830 Bearing wedge Removing ball bearings on crankshaft
20 897714-24330 Oil seal tool Installing ball bearings of gear case
21 363018-00310 Washer Installing crankcase oil seal
22 897726-16431 Oil seal tool Installing crankcase oil seal
23 897702-30131 Piston pin tool Removing and installing piston pin
24 897719-02830 Piston holder Making piston steady to remove and install piston/ring
25 P021-044871 PTO shaft puller Removing driven shaft
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RM-520ES
BP510S SERVICE HINT

2 SERVICE HINT FOR CLUTCH SIDE GEAR CASE

(E)
(D)
(C)

(A)

(B)

(D)

( A ) Gear case (E)

( B ) Driven gear
( C ) Drive gear
( D ) Ball bearing
(G)
( E ) Retaining ring
( F ) Clutch drum
( G ) Clutch case
(F)
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RM-520ES
SERVICE HINT BP510S

2-1 Removing gear case assembly from clutch case

1. Insert socket wrench adapter (A) (6.3mm Drive)

into drive gear (B) to hold driven gear rotaion.
B

2. Remove clutch drum (C) using 2-pin wrench

C 897712-07930 (D), inserting the adapter (A) into
the drive gear as shown.

3. Heat up around driven gear of clutch case (E)

E with a heat gun as shown.

WARNING DANGER
When using a heat gun, wear safety gloves.
Otherwise, a burn will result.

4. Remove gear case assembly (F), tapping driven

gear with a plastic hammer as shown.
G D NOTE: Use a iron block or equivalent (G) to avoid
C
driven gear damage when tapping the gear.

F
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RM-520ES
BP510S SERVICE HINT

2-2 Replacing gears and ball bearings

A 1. Remove retaining ring (A) from gear case (B).

2. Screw connector (Female M10 x 1.25) (C) on

B E driven gear (D). Screw PTO shaft puller (E) on the
connector.

D
C

3. Strike weight (e1) to nut (e2) holding gear case

B (B) to pull out driven gear (D) together with the
D
e1 relative parts.

NOTE: Keep hold weight (e1) while using. The

puller (E) and driven gear (D) could fly out, and
may be damaged.
e2

4. Remove retaining ring (G) from gear case (B).

G

B
5. Heat up the middle of gear case (B) with a heat
gun as shown.

WARNING DANGER
When using a heat gun, wear safety gloves.
Otherwise, a burn will result.

B 6. Tap gear case (B) several times using a plas-

tic hammer until drive gear with two ball bearings
come out as shown.

7. Check drive gear, driven gear, and ball bearings.

If worn or rough rotation is found, replace the parts
as required.
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RM-520ES
SERVICE HINT BP510S

2-2 Replacing gears and ball bearings (continued)

8. Apply small amount of urea based grease on

rolling element (Ball) of ball bearings (h2) and (k2).
J
9. Apply small amount of urea based grease on
gears of driven gear (D) and drive gear (L) as
Gr
ea
se
shown.

NOTE: If old grease on ball bearings or gears is

left, remove it.
e
as
re
G D 10. Install ball bearings (h1) and (h2) on driven
h1
gear (D) using oil seal tool 897726-21430 (J) one
by one.
h2

M
11. Install ball bearings (k1) and (k2) on drive gear
(L) using oil seal tool 897726-21430 (J) one by
J one. Install retaining ring (M) as shown.

L
Grease

e
as
re
G
L
k1

k2

A
12. Heat up gear case (B) with a heat gun.
D 13. Install drive gear (L) into gear case (B) using
oil seal tool 897726-21430 (J).
B 14. Install driven gear (D) into gear case (B) using
oil seal tool 897726-21430 (J).
L
15. Make sure the gears can move smoothly. If it
does not, remove the gears and go back step 12.

NOTE: Do not heat up gear case (B) with driven

gear (D) inserted in gear case (B).
G 16. Apply small amount of thread locking sealant
(Loctite #242, ThreeBond #1324 or equivalent) on
grooves (b1) of gear case (B) for retaining ring (G)
b1
and (A).

NOTE: Do not apply thread locking sealant on

ball bearings. If old thread locking sealant is left in
grooves, remove it.

17. Install retaining rings (G) and (A).

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RM-520ES
BP510S SERVICE HINT

2-2 Replacing gears and ball bearings (continued)

18. Install coller (Q) on driven gear (D).

N
B 19. Assemble gear case assembly (B) to clutch
Q case (N), matching hole (b2) with screw (P).
D

b2 P