McCulloch Model Mini Mac 1 &6 ‘Mini Mac 25 £30 Mini Mac 35, Power Mae 6 SPa0 MAINTENANCE SPARK PLUG. Recommended spark plug is AC CS45T or equivalent. Spark plug electrode gap is 0.025. Note that plug has a tapered seat and does not require a gasket. Tighten spark plug to 4 torque of 144-180 in-Ibs. CARBURETOR. A’ diaphragm type carburetor is used as shown in Fig. MCT2 or MCT-2A. Initial adjustment for idle and high speed mixture screws fs % turns open. High speed mixture ‘on model SP40 is not adjustable due to f fixed main jet. Clockwise rotation of mixture serews will lean fuel mixture Make final adjustments with engine warm and running. High speed mixture ‘adjustment must be made with saw lunder load. Refer to Fig. MCT-1 for location of adjusting screws. Choke and throttle plate on models other than SPAO must be installed as shown in Fig. MCT'3. Note location of dimple (D). Dimple must be in position fon inner side of plate. ‘Lever height should be 0.005:0.020 above carburetor body on Mini-Mac 1 for 6 carburetor with bonded type dia: phragm (21—Fig. MC7-2). Lever height Should be flush with carburetor body ‘on all other models. NOTE: A coarse vent sereen (27) is available for MiniMac 6 earburetor to cation of Fig. MC7-A—View shi ‘al models farburetor adjustment screws “oxcopt SPA. 192 Bore Stroke Inches Inches 1.315 1.200 1375, 1.200 1438 1.201 1.438 1.201 1582 1201 Power Mac 8 chain sam Comuretor om MintMae 35,20 and 38-16 similar. Fig, MC7-28—Exploged ‘Hew of exrburetor used on ‘model S40. } elas, see § Plptem e & Fac ni are Neale Sek valve ie FS poe daptrarm 1g apo sae pla McCULLOCH 1.78 4.78 20 20 23 Drive ‘Type Direct Direct Direct Direct CHAIN SAWSCHAIN SAWS. prevent air blockage to metering dia phragm (21) caused by air obstruction at vent screen, MAGNETO AND TIMING. The mag: eto magnet is cast into the flywheel and the contact breaker points are in a breaker box located below flywheel. Breaker point gap is 0.018. Clearance between legs of coil lami nation and flywheel magnet should be 0.010 and can be adjusted after loosen- ing the mounting screws. Ignition timing is 26 degrees BTDC and is not adjustable. Ignition timing is correct on Mini Mae I and Mini Mac 6 if breaker points open when timing mark fon flywheel is aligned with inner edge of trailing leg of coil lamination. Igni tion timing is correct on Power Mac 6 if breaker points open when timing mark on flywheel is aligned with leading edge of leading leg of coil lamination. LUBRICATION. The engine is lubri- cated with a mixture of regular gaso- Tine and oil. Recommended fuel:oil ratio is 8 0. of oil mixed with each gallon of gasoline (approx. 40:1) when using MeCulloch oil. If MeCulloch oil is not available, use 6 ounces of SAE 40 two-stroke oil for each gallon of gaso- line (approx. 20:1), Fill chain oiler tank each time fuel tank is filled. Use SAE 30 motor oil for ‘be installed on shalte 's8. shown. shove. Dimples (0) must be on inside of plate, temperatures above 40°F and SAE 10 motor oil for lower temperatures. CARBON. If a noticeable lack of power or a decrease in the exhaust noise level is evident, it is possible that muffler and exhaust ports need clean ing. Use a wood seraper when cleaning ‘exhaust ports to avoid damage to eylin der oF piston REPAIRS PISTON, RINGS AND CYLINDER. To remove piston it is necessary to separate crankcase and cylinder as outlined in CRANKSHAFT AND CRANKCASE section. To remove piston pin on all models except SP40, use Piston Tool Kit P/N £85062 for Mini-Mac 1, Mini Mae 6, Mini ‘Mac 25 and Mini-Mac 35 and Tool Kit P/N 68915 for Mini Mae 35 and Power Mae 6. A Yeinch drift pin is used to ess piston pin and a bearing out of iston. Press drift pin through metal fend of one of the pin bearings, then il McT-5—Exploded view of Mini Mac 1, 6, 25, 3 35 ‘and 'SP40' engi vents (108 red of" Power Mac. 6 power: McCulloch press pin and opposite hearing Piston. Remove piston from rod and press out remaining bearing. Bearings must be renewed, due to damage during removal. Piston pin on SPA0 models is retained by two wire retain ers and rides in a caged roller bearing in small end of rod. Cylinder is chromed and piston and rings are available in standard size only. Cylinder should be inspected for wear, seoring or other damage to chromed bore, To instal piston on rod of all models except SP40, proceed as follows: Install one closed end piston pin needle bearing using short leg of guide supplied in Piston Assembly Tool Kit Press bearing in with closed end up. Press carefully as too much pressure will force bearing too far into piston and possibly damage piston. Remove guide, rotate piston 180 degrees, install ‘connecting rod in piston and insert long, leg of guide through open piston pin hole so that guide rests on little end of connecting rod. Drop piston pin into hole of guide as shown in Fig. MC7-8 Mes,McCulloch and press piston pin into connecting od until driver shoulders on guide. Remove driver and guide and press remaining needle hearing into piston, using short leg of guide, following pro- ‘cedure used to install opposite needle bearing. Check to see that connecting ioves freely "fing end gap fs 0.05-0.015 inch; cing side elearanee is 0.0045-0.0070 inch for ‘model SP40 and 0,0030.0.0045 ineh for all other models. Do not try to lap ton rings to gain sufficient ring side clearance; renew piston. Position rings fon piston so that end gaps will be away from exhaust port when installed in cylinder. CONNECTING ROD. Refer to PIS. ‘TON section to remove piston from rod. Unserew rod eap screws to remove rod from crankshaft. Rod bearing has 20 needle rollers. Inspect connecting rod for worn or damaged bearing surfaces. Connecting rod should not be bent or twisted. In spect crankshaft crankpin for waar or scoring. ‘To reassemble, hold bearing rollers using a heavy grease and install rod on crankshaft being sure pips on rod and ‘ap shown in Fig. MC7-7 are aligned. Rod and eap are fractured and serra tions must mate correctly. Tighten rod ‘ap screws to 35-40 in-Ibs. ‘(CRANKSHAFT AND CRANKCASE. ‘To disassemble MiniMac 1, 6, 25, 90, 35 or SP40, proceed as follows: Remove bar with chain and handles. Remove fuel tank cover, rear fan housing as sembly and fuel tank. Remove earbure Fig. MCT8—Foltow procedure outined in {eri for assembling piston, connecting rod, piston pin end. eerings on Mini-Mac. nd ower Mac models. Care must be taken not {o"damage piston when pressing earings. 194 tor, flywheel and ignition and clutch as. semblies. Remove automatic oll pump assembly (1. thru 7—Fig. MCT.) if so equipped, from crankease (10). Un- screw relaining serews and separate ‘erankease (10) from cylinder (22). Re move crankshaft, rod and piston assem bly from erankease and cylinder. ‘To disassemble Power Mac 6, remove chain, bar and fan housing. Remove hhandle and upper and lower shrouds. Remove flywheel and ignition assem bly. Remove oil tank. Unserew crank ease screws and separate crankease (Fig. MCT-6) from cylinder (15). Remove crankshaft, rod and piston assembly from crankease and cylinder. Crankshaft is supported by two needle roller bearings. Bearings on SP40 are contained in sleeves (14A— Fig. MC7'5). Bearings on Power Mac 6 are retained by snap rings (S—Fig. MC7-6). Thrust washers (7) on Power Mac 6 must be installed with chamfer fon inside. Install crankshaft. bearings ‘on all models with lettered end of bearing out Crankease and cylinder have mated surfaces and must not be interchanged. Use a suitable sealant on mating sur faces during assembly. Note that erank case and cylinder must be renewed as a unit. Mini Mae 6 replacement erankease must be drilled to provide a pulse passage on models with automatic oil on all models except Power Mac = ten = i. 5.6 hye 1 MCT gf PowerMac 6 Sette i. cee CHAIN SAWS pump. An indentation is located on the ‘erankease (10—Fig. MCT-5) in the area where the oil pump housing (3) is ‘mounted. A 0.170 drill should be used to make the passage. Crankease (10) should be removed to prevent metal from falling into erankease and eylin- der. Avoid drilling too elose to “O” ring (8) seating area as leakage may result. CLUTCH. To remove cluteh, detach cluteh guard, bar, chain and fan hhousing. Lock the flywheel by inserting 1 serewdriver between bossed portion of flywheel and flywheel nut. Clutch ‘nut has left hand threads. If necessary to renew clutch shoes, renew complete set of shoes. Cheek sprocket for worn rails and pins. In- spect sprocket needle bearing for wear Mac 1, 6, 25, 90, 8 or SP4O clutch spring’ is’ retained by retainer plates (8—Fig. MC7-9). A flat retainer plate or a plate with a bent corner has been used. Plates with a bent comer should be used in place of the flat re tainer plates. Install clutch spring in cluteh shoes with spring ends located where one of the retainer plates is to be installed. Install retainer plate adja ‘cent to clutch spring ends with bent corner of plate up. Install other retain cer plate with bent corner down con tacting spring. ‘Note that different crankshaft, cluteh bearing, drum and. rotor assemb! have been used on Mini Mac 6. Be sure correct assembly is used as some ‘components are not interchangeat “Tighten cluteh, nut to 125-150 nibs Nut has left hand threads and mant- facturer does not recommend using an impact wrench to tighten eluteh nut. ‘MANUAL CHAIN OILER. Refer to Fig. MCT-11 for exploded view of oil pump used on Mini Mae 1, 6, 25, 30, 85 ‘35 and SP40 manual olf pum IST HieCHAIN SAWS 6 78 9 and SP40 with manual chain oiler ‘Three check valves have been used and are colored black, green or gray. Recommended check valve is colored gray. Be sure oil connector and oil dis charge line are properly connected to prevent oil leaks. Fig. MC7-13—Erploded view of automatic ier and manual cller used on some Power Mise "sows. Nate liferonce In size of "0" “ings @) weed on cylinder 1) Fig. Mor-12—ex ‘iow of mancal ol Sembly Used on some "Power Mac 6 saws: rey, ance Refer to Figs. MCT-12 and MC7.13, for exploded views of manual oil pumps uused on Power Mae 6. Note that type shown in Fig. MC7-12 pumps oil using a diaphragm and spring while the manual aier shown in Fig. MCT 18 uses a valve AUTOMATIC CHAIN OILER. Refer to Fig. MC7-13 for exploded view of automatic chain oiler used on Power Mac 6. Oil pump cylinder (1) is re moved by unserewing in counter clock: wise direction. Oil tank (19) must be removed to remove piston assembly. Cheek condition of “O" rings and be sure ll and pressure passages are ‘The automatic chain oiler used on the Mini-Mac 6, 25, 90 and 35 is shown in Fig. MC7-5. Remove front cover and fuel tank to remove automatic oil pump. Some models are equipped with & washer to prevent movement of “0” 1g (9). Washer must be sealed to crankease (10) to prevent I 30 and 35 models have an “O" ring on the pump piston (7) and a piston ring (6) with a smaller LD. These compo. nents should be installed in place of original components if low oil output RECOIL STARTER. To disassemble recoil starter, remove rope handle and allow rope to rewind into starter. Remove fan housing (1—Fig. MCT-14) ‘on MiniMac 1 or 6, Remove starter Fig. Me7-14—E4 ‘iow of Mint Moe Mini-atac 6 reco! McCulloch ‘cover on all other models. Remainder ‘of disassembly is self-evident. Care should be taken when removing rewind ‘spring to prevent injury. Rewind spring should be wound in clockwise direction. Wind rope on pul: ley in clockwise direction when viewing pulley from serew (6—Fig. MCT-14) side. To pre-tension rewind spring, complete starter assembly, pass rope through outlet and install rope handle Pull a small amount of rope back through outlet and engage rope in notch of rope pulley (4). Rotate pulley fone turn clockwise ‘with rope in notch. Pull rope handle and check res ‘action. Repeat procedure until desired rewind action is obtained. Be sure ex- cessive tension is not placed on spring as spring may break when rope is pulled to its full length. Proper tension an be determined by pulling rope to full length and then holding pulley. It should be possible to turn drum an additional Ys-turn clockwise if spring correctly tensioned. CHAIN BRAKE. Models SP40 and later Mini Mac 25 models are equipped with a chain brake which stops chain motion when the operator's hand eon: tacts chain brake lever (8—Fig. MCT 15). The chain brake lever (8) is connected to steel strap (2) and as the brake lever is pushed forward the steel band tightens around the elutch drum thereby. stopping chain motion. Chain bbrake components must operate freely for mechanism to be effective, 195