G2500 / G2500 OPS

848C1B93A1 (704)

G
B
OWNER’S MANUAL

CHAIN SAWS

G2500
G2500 OPS
(One-Push-Start)
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 G2500 / G2500 OPS

EXPLANATION OF SYMBOLS AND SAFETY WARNINGS

Read operator's instruction

Wear head, eye and ear
book before operating this
protection.
machine.

Use the chain saw Warning! Danger of

with two hands. kickback.

Read, understand and Use appropriate protections

follow all warnings. for foot-leg and hand-arm.

Never touch hot surface. This saw is for trained tree

service operators only.

G2500

WARNING!!!
RISK OF DAMAGING HEARING
Wear head, eye and ear protection.

G2500 OPS

WARNING!!!
RISK OF DAMAGING HEARING
Wear head, eye and ear protection.

MODEL SOUND LEVEL VIBRATION LEVEL

EN 608-ISO 7182 2000/14/EC EN608-ISO 7505
LwA
LpA Front handle Rear handle
guaranteed
G2500 25.4 cm3 97.4 dB(A) 110 dB(A) 4.3 m/s2 7.0 m/s2
G2500 OPS 25.4 cm3 96.5 dB(A) 112 dB(A) 6.2 m/s2 5.1 m/s2

APPROVAL NUMBER OF CE EXHAUST EMISSION REGULATION (2002/88/EC)

e13*97/68SH2G3*2002/88*0085*03

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 G2500 / G2500 OPS

G
DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE DECLARATION OF CONFORMITY TO MACHINES DIRECTIVE B
(Directive 98/37/EC, 89/336/EEC) (Directive 98/37/EC, 89/336/EEC)
and to the regulations governing transposition and to the regulations governing transposition
Internal control production Internal control production

MANUFACTURER : ZENOAH CO.,LTD MANUFACTURER : ZENOAH CO.,LTD

No. 9, 1-Chome No. 9, 1-Chome
MINAMIDAI, KAWAGOE City MINAMIDAI, KAWAGOE City
SAITAMA, JAPAN SAITAMA, JAPAN

DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW : DECLARES THAT THE DESIGN OF THE MACHINE DESCRIBED BELOW :

Model : G2500 Model : G2500 OPS

Serial no. : 110001 and up Serial no. : 510001 and up
Make : ZENOAH Make : ZENOAH

CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES CONFORMS TO THE REQUIRMENTS OF THE MODIFIED MACHINES
DIRECTIVE (Directive 98/37/EC) AND TO THE NATIONAL REGULATIONS DIRECTIVE (Directive 98/37/EC) AND TO THE NATIONAL REGULATIONS
GOVERNING ITS TRANSPOSITION ABROAD : AND GOVERNING ITS TRANSPOSITION ABROAD : AND
THAT IT HAS BEEN ISSUED WITH A “CE” CERTIFICATE, THAT IT HAS BEEN ISSUED WITH A “CE” CERTIFICATE, NO. U3 2592658 01
NO. M. 0303. 02. 2737 BY TÜV Rheinland Group - TÜV Rheinland InterCert kft. Product Certification -
BY THE ISTITUTO CERTIFICAZIONE EUROPEA PALAZZO DEL VESCOVO - V. H-1061 Budapest Paulay Ede u. 52 - HUNGARY
GARIBALDI, 20 40011 ANZOLA DELL’ EMILIA - ITALY

Signed in Saitama, Japan 1st April 2007 Signed in Saitama, Japan 1st April 2007

Masahiko GOUDA Masahiko GOUDA

General Manager, Quality Assurance Department General Manager, Quality Assurance Department

Contents
1. For Safe Operation ................................................................... 4
2. Explanation of Symbols on the Machine .................................. 8
3. Installing Guide Bar and Saw Chain ......................................... 9
4. Fuel and Chain Oil .................................................................. 10
5. Operating the Engine ............................................................. 11
6. Sawing .................................................................................... 13
7. Maintenance ........................................................................... 15
8. Maintenance of Saw Chain and Guide Bar ............................ 16
9. Troubleshooting Guide ........................................................... 17
10. Disposal .............................................................................................. 17
11. Specifications ......................................................................... 18
12. Limited Warranty ..................................................................... 19

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10. Always hold the chain saw firmly

1. For safe operation with both hands when the engine
is running. Use a firm grip with
WARNING thumb and fingers encircling the
This chainsaw has been especially designed for chain saw handles.
tree maintenance and should therefore only be
used by trained operators when working on trees.

1. Never operate a chain saw when

you are fatigued, ill, or upset, or 11. Keep all parts of your body away
under the influence of medica- from the saw chain when the en-
tion that may make you drowsy, gine is running.
or if you are under the influence
of alcohol or drugs.
2. Use safety footwear, snug fitting
clothing and eye, hearing and
head protection devices.
Use the vibration-proof glove.
3. Keep the saw chain sharp and
the saw, including the AV system, 12. Before you start the engine,
well maintained. A dull chain will make sure the saw chain is not
increase cutting time, and press- contacting anything.
ing a dull chain through wood will
increase the vibrations transmit- 13. This product is provided with a
ted to your hands. A saw with centrifugal clutch. Accordingly,
loose components or with dam- the saw chain starts to rotate the
aged or worn AV buffers will also moment the choke knob is set to
tend to have higher vibration lev- the “START” position (first step)
els. to start the engine. At the start,
4. All the above mentioned precau- put the machine body on the flat
tions do not guarantee that you ground and pull the starter rope
will not sustain whitefinger dis- while holding the machine body
ease or carpal tunnel syndrome. securely so that the saw chain
Therefore, continual and regular cannot touch the ground and sur-
users should monitor closely the rounding obstacles.
condition of their hands and fin- 14. Don’t pull the starter rope while
gers. pulling the throttle lever (“Start
If any of the above symptoms ap- while pulling”) in the status where
pear, seek medical advice imme- the chain saw is hung with one
diately. hand.
5. Always use caution when han- Doing this operation is strictly
dling fuel. Wipe up all spills and prohibited.
then move the chain saw at least 15. If the saw chain continues to ro-
3 m from the fueling point before tate, stop the engine, and then
starting the engine. readjust the idle adjustment
6. Eliminate all sources of sparks or screw after confirming that there
flame (i.e. smoking, open flames, is no hitch on the throttle lever
or work that can cause sparks) motion.
in the areas where fuel is mixed, 16. Always carry the chain saw with
poured, or stored. the engine stopped, the guide
7. Do not smoke while handling fuel bar and saw chain to the rear,
or while operating the chain saw. and the muffler away from your
8. Do not allow other persons to be body.
near the chain saw when start- 17. Always inspect the chain saw be-
ing or cutting. Keep bystanders fore each use for worn, Ioose, or
and animals out of the work area. damaged parts. Never operate
Children, pets and bystanders a chain saw that is damaged, im-
should be a minimum of 10 m properly adjusted, or is not com-
away when you start or operate pletely and securely assembled.
the chain saw. Be sure that the saw chain stops
9. Never start cutting until you have moving when the throttle control
a clear work area, secure foot- trigger is released.
ing, and a planned retreat path
from the falling tree.
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18. All chain saw service, other than KICKBACK SAFETY PRECAU-
the items listed in the Owner’s TIONS FOR CHAIN SAW US-
Manual, should be performed by ERS
competent chain saw service
personnel. (E.g., if improper tools WARNING
are used to remove the flywheel,
or if an improper tool is used to • Kickback may occur when the
hold the flywheel in order to re- nose or tip of the guide bar G
move the clutch, structural dam- touches an object, or when the B
age to the flywheel could occur wood closes in and pinches the
which could subsequently cause saw chain in the cut. Tip contact
the flywheel to disintegrate.) in some cases may cause a light-
19. Always shut off the engine be- ning fast reverse reaction,kicking
fore setting it down. the guide bar up and back to
20. Use extreme caution when cut- wards the operator. Pinching the
ting small size brush and sap- saw chain along the top of the
lings because slender material guide bar may push the guide
may catch the saw chain and be bar rapidly back towards the op-
whipped toward you or pull you erator. Either of these reactions
off balance. may cause you to Iose control of
21. When cutting a limb that is un- the saw, which could result in se-
der tension, be alert for spring- rious personal injury.
back so that you will not be • Do not rely exclusively on the
struck when the tension in the safety devices built into your saw.
wood fibers is released. As a chain saw user you should
22. Never cut in high wind, bad take several steps to keep cut-
weather, when visibility is poor or ting jobs free from accident or
in very high or low temperatures. injury.
Always check the tree for dead (1) With a basic understanding of
branches which could fall during kickback you can reduce or
the felling operation. eliminate the element of surprise.
Sudden surprise contributes to
23. Keep the handles dry, clean and accidents.
free of oil or fuel mixture. (2) Keep a good grip on the saw with
24. Operate the chain saw only in both hands, the right hand on the
well ventilated areas. Never start rear handle, and the left hand on
or run the engine inside a closed the front handle, when the engine
room or building. Exhaust fumes is running. Use a firm grip with
contain dangerous carbon mon- thumbs and fingers encircling
oxide. the chain saw handles. A firm
25. Do not operate the chain saw in grip will help you reduce kick-
a tree unless specially trained to back and maintain control of the
do so. saw.
26. Guard against kickback. Kick-
back is the upward motion of the (3) Make certain that the area in
guide bar which occurs when the which you are cutting is free from
saw chain at the nose of the obstructions. Do not let the nose
guide bar contacts an object. of the guide bar contact a log,
Kickback can lead to dangerous branch, or any other obstruction
loss of control of the chain saw. which could be hit while you are
operating the saw.
27. When transporting your chain (4) Cut at high engine speeds.
saw, make sure the appropriate
guide bar scabbard is in place. (5) Do not overreach or cut above
shoulder height.
28. Never touch the muffler guard,
(3)
guide bar or saw chain with bare (6) Follow the manufacturer’s sharp-
hands while the engine is in op- ening and maintenance instruc-
(2) eration or immediately after shut- tions for the saw chain.
(1)
ting down the engine. Doing so
could result in serious burns be- (7) Only use replacement bars and
(1) muffler guard cause of high temperature. chains specified by the manufac-
(2) guide bar turer or the equivalent.
(3) saw chain
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WORKING WITH TREE SERVICE CHAIN-SAWS The saw should only be attached to the recommended
FROM A ROPE AND HARNESS attachment points on the harness. These may be at
This chapter sets out working practices to reduce the mid-point (front or rear) or at the sides. Where possible
risk of injury from tree service chainsaws when working attaching the saw to centre rear mid-point will keep it
at height from a rope and harness. While it may form clear of climbing lines and support its weight centrally
the basis of guidance and training literature, it should down the operator’s spine.
not be regarded as a substitute for formal training.

General requirements working at height

Operators of tree service chainsaws working at height
from a rope and harness should never work alone. A
competent ground worker trained in appropriate emer-
gency procedures should assist them.
Operators of tree service chainsaws for this work should
be trained in general safe climbing and work position-
ing techniques and shall properly equipped with har-
nesses, ropes, strops, karabiners and other equipment
for maintaining secure and safe working positions for
both themselves and the saw.

Preparing to use the saw in the tree When moving the saw from any attachment point to an-
The chainsaw should checked, fuelled, started and other, operators should ensure it is secured in the new
warmed up by the ground worker before it is sent up to position before releasing it from the previous attachment
the operator in the tree. The chainsaw should be fitted point.
with a suitable strop for attaching to the operator’s har-
ness: Using the chainsaw in the tree
An analysis of accidents with these saws during tree
service operations shows the primary cause as being
inappropriate one-handed use of the saw. In the vast
majority of accidents, operators fail to adopt a secure
work position witch allows them to hold both handles of
the saw. This results in an increased risk of injury due
to:
• not having a firm grip on the saw if it kicks back;
• a lack of control of the saw such that it is more liable
to contact climbing lines and operators body (par-
ticularly the left hand and arm)
• losing control from insecure work position resulting
in contact with the saw (unexpected movement dur-
a) choke the strop around the attachment point on the ing operation of the saw)
rear of the saw (A);
Securing the work position for two-handed use
To allow the operator to hold the saw with both hands,
they should as general rule, aim for secure work posi-
tion where they are operating the saw at:
• hip level when cutting horizontal sections;
• solar plexus level when cutting vertical sections.

Where the operator is working close into vertical stems

with a low lateral forces on their work position, then a
good footing may be all that is needed to maintain a
b) provide suitable karabiners to allow indirect (i.e. via secure work position. However as operators move away
the strop) and direct attachment (i.e. at the attach- from the stem, they will need to take steps to remove or
ment point on the saw) of saw to the operators har- counteract the increasing lateral forces by, for example,
ness; a re-direct of the main line via a supplementary anchor
c) ensure the saw is securely attached when it is being point or using an adjustable strop direct from the har-
sent up to the operator; ness to a supplementary anchor point.
d) ensure the saw it secured to the harness before it is
disconnected from the means of ascent.

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 G2500 / G2500 OPS

One-hand use of the chainsaw

Operators should not use tree service chainsaws one-
handed in place of unstable work positioning or in pref-
erence to a handsaw when cutting small diameter wood
at the branch tips.
Tree service chainsaws should only be used one-handed
where:
• the operator cannot gain a work position enabling two- G
handed use; and B
• they need to support their working position with one
hand; and
• the saw is being used at full stretch, at right angles to
Gaining a good footing at the working position can be and out of line with the operator’s body.
assisted by use of a temporary foot stirrup created from
an endless sling.

Starting the saw in the tree Operators should never:

When starting the saw in the tree, the operator should: • cut with the kickback zone at the tip of the chainsaw
a) apply the chain brake before starting; guide bar
b) hold saw on either the left or right of the body when • ‘hold and cut’ sections
starting: • attempt to catch falling sections.
1) on the left side hold the saw with either the left hand
on the front handle or the right hand on the rear Freeing a trapped saw
handle and thrust the saw away from the body while If the saw should become trapped during cutting, op-
holding the pull starter cord in the other hand; erators should:
2) on the right side, hold the saw with the right hand on • switch off the saw and attach it securely to the tree
either handle and thrust the saw away from the body inboard (i.e. towards the truck side) of the cut or to a
while holding the pull starter cord in the left hand. separate tool line;
• pull the saw from the kerf whilst lifting the branch as
The chain brake should always be engaged before low- necessary;
ering a running saw onto its strop. • if necessary, use a handsaw or second chain saw to
Operators should always check the saw has sufficient release the trapped saw by cutting a minimum of 30
fuel before undertaking critical cuts. cm away from the trapped saw.

Whether a handsaw or a chainsaw is used to free a stuck

saw, the release cuts should always be outboard (to-
ward the tips of the branch), in order to prevent the saw
being taken with the section and further complicating
the situation.

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2. Explanation of Symbols on the Machine

WARNING For safe operation and maintenance, symbols are carved in relief on the machine.
According to these indications, please be careful not to make any mistake.

The port to refuel “MIX GASOLINE”

Position: Fuel cap

The port to top up chain oil

Position: Oil cap

Setting the switch to the “O” position, the engine stops immediately.
Position: Front at the top of the rear handle

Starting the engine. If you pull out the choke knob (at the back-right of
the rear handle) to the point of the arrow, you can set the starting mode
as follows:
• First-stage position – starting mode when the engine is warm.
• Second-stage position – starting mode when the engine is cold.
Position: Upper-right of the aircleaner cover

The screw under the “H” stamp is The High-speed adjustment screw.
The screw under the “L” stamp is The Slow-speed adjustment screw.
The screw at the left of the “T” stamp is the Idle adjustment screw.
Position: Left side of the rear handle

Shows the directions that the chain brake is released (white arrow) and
activated (black arrow).
Position: Front of the chain cover

If you turn the rod by screwdriver follow the arrow to the "MAX" position,
the chain oil flow more, and if you turn to the "MIN" position, less.
Position: Bottom of the power unit

<G2500 One-push-start only>

A A : Indicates the operation selecting position of the select lever for the
One-push-start and Super e-START at a start of the recoil.

B : Indicates the operating direction of the select lever at a start of the

engine by One-push-start.
B Position: Upper side portion of the recoil starter

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3. Installing Guide Bar and Saw Chain

A standard saw unit package contains the items as illustrated.

Power unit
Bar protector
Plug wrench G
Guide bar
B

Saw chain

Screwdriver for
carburetor adjustment

Open the box and install the guide bar and the saw 5. Fit the chain tensioner nut into the lower hole of the
chain on the power unit as follows: guide bar, then install the chain cover, and fasten
the mounting nut to finger tightness.
WARNING
The saw chain has very sharp edges. Use thick pro-
tective gloves for safety.

1. Pull the guard towards the front handle to check that

the chain brake is not engaged.
2. Loosen the nuts and remove the chain cover.
3. Fix the hanger on the rear of power unit by screw.

Hanger WARNING
When installing the chain cover, be sure to fit the hook
completely at the rear end of the cover.

6. While holding up the tip of the bar, adjust the chain

tension by turning the tensioner screw until the tie
straps just touch the bottom side of the bar rail.
Tensioner screw
4. Mount the guide bar then fit the saw chain around
the bar and sprocket.

Loosen

Hole
Tighten

Chain tensioner nut 7. Tighten the nuts securely with the bar tip held up
Chain cover (11.8-14.7 N.m./120-150 kg-cm). Then check the
chain for smooth rotation and proper tension while
moving it by hand. If necessary, readjust with the
NOTE chain cover loose.

Pay attention to the correct direction of the saw chain.

Moving direction
Tighten

8. Tighten the tensioner screw.

WARNING
A new chain will expand its length in the beginning of
use. Check and readjust the tension frequently as a loose
chain can easily derail or cause rapid wear of itseif and
the guide bar.
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4. Fuel and Chain Oil

■ FUEL 4. Pour in the rest of gasoline and agitate again for at
least one minute. As some oils may be difficult to
WARNING
agitate depending on oil ingredients, sufficient agi-
• Gasoline is very flammable. Avoid smoking or tation is necessary for the engine to last long. Be
bringing any flame or sparks near fuel. Make sure careful that, if the agitation is insufficient, there is an
to stop the engine and allow it cool before refuel- increased danger of early piston seizing due to ab-
ing the unit. Select outdoor bare ground for fuel- normally lean mixture.
ing and move at least 3 m (10 ft) away from the 5. Put a clear indication on the outside of the container
fueling point before starting the engine. to avoid mixing up with gasoline or other contain-
ers.
6. Indicate the contents on outside of container for easy
identification.

■ FUELING THE UNIT

1. Untwist and remove the fuel cap. Rest the cap on a
dustless place.
2. Put fuel into the fuel tank to 80% of the full capacity.
3. Fasten the fuel cap securely and wipe up any fuel
• The Zenoah engines are lubricated by oil specially
spillage around the unit.
formulated for air-cooled 2-cycle gasoline engine use.
If Zenoah oil is not available, use an anti-oxidant added WARNING
quality oil expressly labeled for air-cooled 2-cycle
1. Select bare ground for fueling.
engine use (JASO FC GRADE OIL or ISO EGC
2. Move at least 10 feet (3 meters) away from the fuel-
GRADE).
ing point before starting the engine.
• Do not use BIA or TCW (2-stroke water-cooling type)
3. Stop the engine before refueling the unit. At that time,
mixed oil.
be sure to sufficiently agitate the mixed gasoline in
the container.

■ FOR YOUR ENGINE LIFE, AVOID:

1. FUEL WITH NO OIL (RAW GASOLINE) – It will cause
severe damage to the internal engine parts very
quickly.
2. GASOHOL – It can cause deterioration of rubber and/
or plastic parts and disruption of engine lubrication.
■ RECOMMENDED MIXING RATIO 3. OIL FOR 4-CYCLE ENGINE USE – It can cause spark
GASOLINE 50 : OIL 1 plug fouling, exhaust port blocking, or piston ring
<when using ZENOAH genuine oil> sticking.
4. Mixed fuels which have been left unused for a
• Exhaust emission are controlled by the funda- period of one month or more may clog the carbu-
mental engine parameters and components (eq., retor and result in the engine failing to operate prop-
carburation, ignition timing and port timing) with- erly.
out addition of any major hardware or the intro- 5. In the case of storing the product for a long period
duction of an inert material during combustion. of time, clean the fuel tank after rendering it empty.
• These engines are certified to operate on unleaded Next, activate the engine and empty the carburetor
gasoline. of the composite fuel.
• Make sure to use gasoline with a minimum octane 6. In the case of scrapping the used mixed oil con-
number of 89RON (USA/Canada: 87AL). tainer, scrap it only at an authorized repository site.
• If you use a gasoline of a lower octane value than
prescribed, there is a danger that the engine tem- NOTE
perature may rise and an engine problem such as As for details of quality assurance, read the description in the
piston seizing may consequently occur. section Limited Warranty carefully. Moreover, normal wear and
• Unleaded gasoline is recommended to reduce the change in product with no functional influence are not cov-
contamination of the air for the sake of your health ered by the warranty. Also, be careful that, if the usage in the
and the environment. instruction manual is not observed as to the mixed gasoline,
• Poor quality gasolines or oils may damage sealing etc. described therein, it may not be covered by the warranty.
rings, fuel lines or fuel tank of the engine.
■ CHAIN OIL
■ HOW TO MIX FUEL Use motor oil SAE #10W-30 all year round or SAE
WARNING #30 ~ #40 in summer and SAE #20 in winter.
• Pay attention to agitation.

1. Measure out the quantities of gasoline and oil to be

mixed.
2. Put some of the gasoline into a clean, approved fuel
container. NOTE
3. Pour in all of the oil and agitate well. Do not use wasted or regenerated oil that can cause
damage to the oil pump.
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 G2500 / G2500 OPS

5. Operating the Engine

WARNING NOTE
It is very dangerous to run a chainsaw that mounts broken When restarting immediately after stopping the en-
parts or lacks any parts. gine, set the Choke knob in the first-stage position
Before starting engine, make sure that all the parts includ- (choke open and throttle lever in the starting posi-
ing bar and chain are installed properly. tion). G
■ STARTING THE ENGINE
Once the choke knob has been pulled out, it will not B
return to the operating position even if you press
Normal start down on it with your finger. When you wish to return
1. Fill fuel and chain oil tanks respectively, and tighten the choke knob to the operating position, pull out
the caps securely. the throttle lever instead.

5. While holding the saw unit securely on the ground,

pull the starter rope vigorously.
Fuel
Chain oil
2. Continuously push the priming bulb until fuel comes
in the bulb.

WARNING

Do not start the engine while the chain saw hangs in

one hand. The saw chain may touch your body. This
in very dangerous.
6. When engine has ignited, first push in the choke knob
3. Set the switch to “I” position. to the first-stage position and then pull the starter
Throttle again to start the engine.
Switch interlock 7. Allow the engine to warm up with the throttle lever
pulled slightly.

Throttle
lever One-push-start
(G2500 OPS) (G2500 OPS only)
• Move the select lever to the machine back side
WARNING
indicated by label until it is stopped, and then set
this lever to the recoil start mode. • Use One-push-start after performing warming-up by
Recoil Start in the status where the machine body is
Select lever securely fixed. You can not use OPS when the engine
Select lever is cold.
operating direction • The starting performance of the engine depends on
the adjustment of the engine. Ask the distributor to
adjust the engine if possible.
• Be careful not to set OPS in motion except when
starting the engine. If so, it may lead to serious injury.
Label
1. Move the select lever to the front side of the machine
4. Pull out the choke knob to the second-stage position. body indicated by label until it is stopped, and set
The choke will close and the throttle lever will then this lever to the One-push-start mode.
be set in the starting position.

Choke When the engine is cool

knob When the engine is warm up
After the engine starts

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 G2500 / G2500 OPS

2. Put the machine body on the stable ground and make 2. When the outside temperature is below 0°C, repeat
sure that there is no obstacle around the saw-crossing the above warming-up operation twice or more. After
portion. Then, while holding the front handle with the the engine stops, use the product in a shorter leaving
left hand and putting the right foot on the frame portion, time.
pull out the starter rope slowly. WARNING

• Be sure to perform warming-up with the guide bar

and the saw chain mounted.
• Keep clear of the saw chain as it will start rotatIng
upon starting of engine.
• Before you start the engine, make sure the saw chain
is not contacting anything.
NOTE

The rope may be pulled out little by little several times.

■ CHECKING THE OIL SUPPLY
WARNING
WARNING
• When pulling out the rope, large clanging is produced.
With this clanging, stop pulling out the rope at once. Make sure to set up the bar and the chain when checking the
This sound notifies that One-push-start has been set. oil supply.
• Don’t pull out the rope excessively or don’t pull it out If not, the rotating parts may be exposed. It is very dangerous.
without load by the starter only, otherwise a starter
failure will occur. After starting the engine, run the chain at medium speed
and see if chain oil is scattered off as shown in the fig-
3. Before starting the engine, fix the engine securely ure.
and make sure that there is no obstacle around the
saw chain. Then, push the top of the engine stop
switch on the right side of the rear handle and set it Chain oil
to the “Run” position. After that, move the select le-
ver to the rear side of the machine body indicated
by label. The starter is started to start the engine.
The chain oil flow can be changed by inserting a
I (Run) O (Stop) Engine stop switch screwdriver in the hole on bottom of the clutch side.
Adjust according to your work conditions.

Rich
Chain oil flow
Select lever Lean adjusting shaft
The oil tank should become nearly empty by the time
fuel is used up. Be sure to refill the oil tank every time
when refueling the saw.

■ ADJUSTING THE CARBURETOR

Label Idle adjusting

screw
NOTE H needle
If the engine cannot be started by the above proce-
dure, repeat the above operations again. If the en- L needle
gine cannot be started smoothly, it may be neces-
sary to add warming-up or readjust the engine. Per- The carburetor on your unit has been factory adjusted,
form warming-up enough and ask the distributor to but may require fine tuning due to a change in operat-
readjust the engine. ing conditions.
Before adjusting the carburetor, make sure that the pro-
■ FOR SMOOTHER USE OF ONE-PUSH-START
vided air/fuel filters are clean and fresh and the fuel prop-
To use One-push-start more smoothly, it is important
erly mixed.
to perform warming-up longer than ever.
1. When the outside temperature is 0° or more, perform
When adjusting, take the following steps:
warming-up for about 5 seconds with the throttle fully
opened. And leave the product for 5 minutes or less NOTE
after the engine stops. Then, use the product. With
Be sure to adjust the carburetor with the bar chain at-
this, the engine can be started more securely.
tached.
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 G2500 / G2500 OPS

1. H and L needles are restricted within the number of WARNING

turn as shown below.
• When the brake operates, release the throttle lever
to slow down the engine speed. Continuous opera-
H needle : -1/4
tion with the brake engaged will generate heat from
L needle : -1/4
the clutch and may cause trouble.
• At machine inspection prior to each job, check the
2. Start the engine and allow it to warm up in low speed
operating condition of the brake following the steps.
for a few minutes. G
3. Turn the idle adjusting screw (T) counterclockwise
1. Start the engine and grasp the handle securely with B
so that the saw chain does not turn. If the idling
both hands.
speed is too slow, turn the screw clockwise.
2. Pulling the throttle lever to maintain the chain opera-
4. Make a test cut and adjust the H needle for best
tion, push the brake lever (left-hand guard) down
cutting power, not for maximum speed.
toward the front using the back of your left hand.
3. When the brake operates and the chain is stopped,
■ CHAIN BRAKE
release the throttle lever.
The chain brake is a device which stops the chain in-
4. Release the brake.
stantaneously if the chain saw recoils due to kickback.
Normally, the brake is activated automatically by inertial Release
Activate
force. It can also be activated manually by pushing the the brake.
brake lever (left-hand guard) down toward the front.
When the brake operates, a yellow cone pops up from
the base of the brake lever.

Releasing the Brake

■ STOPPING THE ENGINE
Pull the brake lever up toward the left-hand handle until
1. Release the throttle lever to allow the engine to idle
it clicks into place.
for a few minutes.
2. Set the switch to the “O” (STOP) position.

Switch

6. Sawing
WARNING
• Before proceeding to your job, • It is not necessary to force the saw into the cut. Ap-
read the section “For Safe ply only light pressure while running the engine at
Operation”. It is recommended full throttle.
to first practice sawing easy • When the saw chain is caught in the cut, do not
logs. This also helps you get attempt to pull it out by force, but use a wedge or a
accustomed to your unit. lever to open the way.

■ GUARD AGAINST KICKBACK

• Always follow the safety regu-
lations. The chain saw must
only be used for cutting wood.
It is forbidden to cut other
types of material. Vibrations
and kickback vary with differ-
ent materials and the require-
ments of the safety regulations
would not be respected. Do
not use the chain saw as a le-
ver for lifting, moving or split-
ting objects. Do not lock it over
fixed stands. It is forbidden to
hitch tools or applications to
the PTO other than those
specified by the manufacturer.
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 G2500 / G2500 OPS

• This saw is equipped with a chain A log lying on the ground

brake that will stop the chain in the
event of kickback if operating prop-
erly. You must check the chain brake
operation before each usage by run-
ning the saw at full the throttle for I -
2 seconds and pushing the front
hand guard forward. The chain
Saw down halfway, then roll the log over and cut from
should stop immediately with the
the opposite side.
engine at full speed. If the chain is
slow to stop or does not stop, re- A log hanging off the ground
place the brake band and clutch
drum before use.
• It is extremely important that the
chain brake be checked for proper
operation before each use and that
the chain be sharp in order to main-
tain the kickback safety level of this
saw. Removal of the safety devices,
inadequate maintenance, or incor-
rect replacement of the bar or chain In area A, saw up from the bottom one-third and finish
may increase the risk ot serious per- by sawing down from the top. In area B, saw down from
sonal injury due to kickback. the top one-third and finish by sawing up from the bot-
tom.
■ FELLING A TREE
Cutting the limbs of Fallen Tree

Felling direction

Notch cut Felling cut

1. Decide the felling direction considering the wind,

First check to which side the limb is bent. Then make
lean of the tree, location of heavy branches, ease of
the initial cut from the bent side and finish by sawing
completing the task after felling and other factors.
from the opposite side.
2. While clearing the area around the tree, arrange a
good foothold and retreat path. WARNING
3. Make a notch cut one-third of the way into the tree Be alert to the springing back of a cut limb.
on the felling side.
4. Make a felling cut from the opposite side of the notch
and at a level slightly higher than the bottom of the Pruning of Standing Tree
notch.

WARNING
When you fell a tree, be sure to warn neighboring work-
ers of the danger.

Bucking and Limbing

WARNING
• Always ensure your foothold. Do not stand on the log.
• Be alert to the rolling over of a cut log. Especially when Cut up from the bottom, finish down from the top.
working on a slope, stand on the uphill side of the
WARNING
log.
• Follow the instructions in “For Safe Operation” to avoid • Do not use an unstable foothold or ladder.
kickback of the saw. • Do not overreach.
• Do not cut above shoulder height.
Before starting work, check the direction of bending • Always use both your hands to hold the saw.
force inside the log to be cut. Always finish cutting from
the opposite side of the bending direction to prevent
the guide bar from being caught in the cut.
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 G2500 / G2500 OPS

7. Maintenance
WARNING WARNING
Before cleaning, the inspecting or repairing the unit, make sure When returning the filter, use a pinch not to be folded the suc-
that engine has stopped and is cool. Disconnect the spark tion pipe.
plug to prevent accidental starting.
3. Oil filter
■ MAINTENANCE AFTER EACH USE 1. With a wire hook, take out the oil filter from the feeding G
1. Air filter port. B
Loosen the knob and remove the air cleaner cover. Take off the
filter elements and tap off attached sawdust. When they are
extremely dirty, shakewash with gasoline. Dry them completely
before reinstalling.

Oil filter

2. Wash the filter with gasoline.

WARNING
When returning the filter, use a pinch not to be folded the suc-
tion pipe.
2. Oiling port 4. Spark plug
Dismount the guide bar and check the oiling port for clogging.

Champion
RCJ-7Y

Oiling port
Clean the electrodes with a wire brush and reset the gap to
0.6 mm as necessary.
3. Guide bar
When the guide bar is dismounted, remove sawdust in the bar 5. Sprocket
groove and the oiling port.
<Type : sprocket nose>
Grease the nose sprocket from the feeding port on the tip of
the bar.

Grease port
Sprocket Check for cracks and for excessive wear interfering with the
Oiling port
chain drive. If the wear is considerable, replace it with new
one. Never fit a new chain on a worn sprocket, or a worn chain
on a new sprocket.
6. Way of the cooling air
4. Others WARNING
Check for fuel leakage and loose fastenings and damage to
major parts, especially handle joints and guide bar mounting. • The engine metal parts can burn your skin. Never touch the
If any defects are found, make sure to have them repaired cylinder, muffler or ignition plug etc. during operation or right
before operating the saw again. after stopping the engine.
• Before starting the engine, check around the muffler and
■ PERIODICAL SERVICE POINTS take off sawdust. If you do not, it will cause the overheating
1. Cylinder fins and a fire. For preventing the trouble, please keep clean
1. Remove the starter case. around the muffler.
2. Remove sawdust between the cylinder
fins. This engine is air-cooled. Dust clogging between the inlet port
3. Clean the valute area. of the cooling air and cylinder fins will cause overheating of
the engine. Periodically check and clean the cylinder fins after
removing the air cleaner and the cylinder cover.

2. Fuel filter
(a) Using a wire hook, take out the filter from the filler port.
inlet port of the cooling air

Fuel filter
IMPORTANT

(b) Wash the filter with gasoline. When installing the cylinder cover, make sure that switch wires
Replace with new one if clogged with dirt completely. and grommets are positioned correctly in place.
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 G2500 / G2500 OPS

7. Muffler 8. Recoil Starter

• For recoil maintenance, when attaching or detaching the
WARNING starter of One-push-start model, the select lever should
If you do not attach the muffler correctly, after engine starts, be in the position of the rear side (G2500 One-push-start
the muffler will be loosen and the hightemperature exhaust only).
gas spout. After cleaning the muffler, pay attention to fit up • Don't pull the starter when detaching it from the unit. It will
the muffler according to the explanation as follows. cause machine defect or serious injury by touching rotat-
ing parts on your body part carelessly.
1. Muffler body, muffler cover and baffle will be combined Select lever
correctly.

Set direction

2. Be sure the gasket is not broken. If it is broken, change to

WARNING
the new one.
3. Before tightening the screw, rub the gross on it. Don't pull the starter when detaching it from the unit.
4. After making a test run, re-tighten the screw (TORQUE:
6.9-7.8 N.m./70-80 kg-cm)
WARNING
Right after stopping the engine, do not touch the muffler
with one's bare hands. It will cause to burn your hands.

If carbon clogs between the muffler, it will cause the poor-out-

put and the trouble in starting. After each 100 hours, check
and clean inside the muffler.

8. Maintenance of Saw Chain and Guide Bar

■ Saw Chain Place the file on the cutter and push straight forward.
Keep the file position as illustrated.
WARNING
It is very important for smooth and safe operation to
always keep the cutters sharp.

The cutters need to be sharpened when:

• Sawdust becomes powder-like.
• You need extra force to saw in.
• The cut path does not go straight.
• Vibration increases.
• Fuel consumption increases.

Cutter setting standards:

WARNING
Be sure to wear safety gloves.

Before filing: After each cutter has been filed, check the depth gauge
• Make sure the saw chain is held securely. and file it to the proper level as illustrated.
• Make sure the engine is stopped.
• Use a round file of proper size for the chain.
Chain type: 91VG / 25AP
File size: 5/32 in (4.0 mm)
Appropriate gauge checker

Make the shoulder round

.025″ (0.64 mm)
Depth gauge standard

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 G2500 / G2500 OPS

WARNING side of a cutter. If a gap is observed between them,

the rail is normal. Otherwise, the bar rail is worn.
Be sure to round off the front edge to reduce the Such a bar needs to be corrected or replaced.
chance of kickback or tie-strap breakage.
Ruler
Make sure every cutter has the same length and edge
angles as illustrated.
Gap G
Cutter length
B

No gap
Filing angle
Chain tilts

Side plate angle WARNING:

This saw is equipped with one of the following low
kickback bar/chain combinations:
Top plate cutting angle Zenoah Part Number
Bar Size Guide Bar Saw Chain Drum
■ Guide Bar 10 2475-52110 2475-52210 2475-51110
• Reverse the bar occasionally to prevent partial wear. 10 2475-52120 3622-52210 2841-51110
• The bar rail should always be square. Check for wear
of the bar rail. Apply a ruler to the bar and the out

9. Troubleshooting Guide
Case 1. Starting failure Case 2. Lack of power/Poor acceleration/
Rough idling
WARNING
Check fuel for water
Make sure the icing prevention system is not work- Replace with proper
ing.
or substandard mix- a fuel.
ture.
Check fuel for water
Replace with proper d
or substandard mix- a fuel. Check air filter and
ture.
fuel filter for clog- a Clean.
d Remove and dry the ging.
Check for engine spark plug.
flooding. a Then pull the starter d
again with no choke. Check carburetor
d for inadequate ad- a
Readjust speed
needles.
Replace with a new
Check spark ignition. a plug.
justment.

Case 3. Oil does not come out

Check oil for sub-
standard quality. a Replace.

d
Check oil passage
and ports for clog- a Clean.
ging.
10. Disposal
When disposing your machine, fuel or oil for the machine, be If the unit seems to need further service, please consult
sure to allow your local regulations. with an authorized service shop in your area.

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 G2500 / G2500 OPS

11. Specifications
Power unit: Cutting head:
G2500 / G2500 OPS <Sprocket bar>
Displacement (cm3): ............................................. 25.4 Sprocket: .................................................................. 6T
Fuel: ................ Mixture (Gasoline 50 : Two-cycle oil 1) Chain speed at max. power ......................... 17.1 (m/s)
(when using ZENOAH genuine oil) Guide bar
Fuel tank capacity (cm3): ....................................... 230 Type: ................................................ Sprocket nose
Chain oil: ................................. Motor oil SAE# 10W-30 Size (in. (cm)): .............................................. 10 (25)
Oil tank capacity (cm3): .......................................... 160 Saw chain
Carburetor: ......................................... Diaphragm type Type: ................................................. Oregon 91VG
lgnition system:: .......................................... Solid State Pitch (in. (mm)): ........................................ 3/8 (9.53)
Spark plug: ...................................... Champion RCJ-7Y Gauge (in. (mm)): ................................... 0.05 (1.27)
Oil feeding system: ......................... Mechanical pump <Hard nose bar>
Max. speed ............................................ 12,500 (min-1) Sprocket: .................................................................. 8T
Idle speed ................................................ 2,900 (min-1) Chain speed at max. power ......................... 15.2 (m/s)
Guide bar
G2500 Type: ....................... ZENOAH carving (Hard nose)
Dimensions (L x W x H) (mm): ............ 265 x 220 x 220 Size (in. (cm)): .............................................. 10 (25)
Dry weight Saw chain
Power unit only (kg): ............................................... 2.9 Type: .................................................. Oregon 25AP
Power: ......................................... 0.96/9,000 (kw/min-1) Pitch (in. (mm)): ........................................ 1/4 (6.35)
Gauge (in. (mm)): ................................... 0.05 (1.27)
G2500 OPS (One-push-start)
Dimensions (L x W x H) (mm): ............ 265 x 235 x 220 G2500 series are equipped with Chain Brake.
Dry weight Specifications are subject to change wihout notice.
Power unit only (kg): ............................................... 3.1
Power: ......................................... 0.88/9,000 (kw/min-1)

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 G2500 / G2500 OPS

12. Limited warranty

Should any failure occur on the product under normal SHALL NOT REDUCE THE WARRANTY OBLIGATION
operating conditions within the applicable warranty pe- OF THE COMPANY.
riod, the failed part will be replaced or repaired free of
charge by a ZENOAH authorized dealer. THE COMPANY IS LIABLE FOR DAMAGES TO OTHER
ENGINE COMPONENTS CAUSED BY THE FAILURE OF
WARRANTY PERIOD: 1 year (6 months if used profes- A WARRANTED PART STILL UNDER WARRANTY. G
sionally, and 30 days if used for rental purpose) from B
the date of initial purchase. THE WARRANTY DOES NOT APPLY TO THOSE
UNITS WHICH HAVE BEEN DAMAGED BY NEGLI-
THE PURCHASER SHALL BEAR COSTS OF TRANS- GENCE OF INSTRUCTION LISTED IN THE OWNER/
PORTING THE UNIT TO AND FROM THE ZENOAH OPERATOR MANUAL FOR PROPER USE AND MAIN-
DEALER. TENANCE OF THE UNITS ACCIDENT MISHANDLING,
ALTERATION, ABUSE, IMPROPER LUBRICATION, USE
THE PURCHASER SHALL NOT BE CHARGED FOR DI- OF ANY PARTS OR ACCESSORIES OTHER THAN
AGNOSTIC LABOR WHICH LEADS TO THE DETERMI- THOSE SPECIFIED BY THE COMPANY, OR OTHER
NATION THAT A WARRANTED PART IS DEFECTIVE, IF CAUSES BEYOND THE COMPANY'S CONTROL.
THE DIAGNOSTIC WORK IS PERFORMED AT THE
ZENOAH DEALER. THIS WARRANTY DOES NOT COVER THOSE PARTS
REPLACED BY NORMAL WEAR OR HARMLESS
THE PURCHASER OR OWNER IS RESPONSIBLE FOR CHANGES IN THEIR APPEARANCE.
THE PERFORMANCE OF THE REQUIRED MAINTE-
NANCE AS DEFINED BY THE MANUFACTURER IN THE THERE ARE NO OTHER EXPRESS WARRANTIES.
OWNER/OPERATOR MANUAL.
IMPLIED WARRANTIES INCLUDING THOSE OF MER-
ANY WARRANTED PART WHICH IS NOT SCHEDULED CHANTABILITY AND FITNESS FOR A PARTICULAR
FOR REPLACEMENT AS REQUIRED MAINTENANCE, PURPOSE ARE LIMITED TO TWO (2) YEARS OF HOME
OR WHICH IS SCHEDULED ONLY FOR REGULAR IN- USE [ONE (1) YEAR FOR ANY OTHER USE] FROM THE
SPECTION TO THE EFFECT OF REPAIR OR “REPLACE ORIGINAL DELIVERY DATE.
AS NECESSARY” SHALL BE WARRANTED FOR THE
WARRANTY PERIOD. ANY WARRANTED PART WHICH LIABILITIES FOR INCIDENTAL OR CONSEQUENTIAL
IS SCHEDULED FOR REPLACEMENT AS REQUIRED DAMAGE UNDER ANY AND ALL WARRANTIES ARE
MAINTENANCE SHALL BE WARRANTED FOR THE EXCLUDED.
PERIOD OF TIME UP TO THE FIRST SCHEDULED RE-
PLACEMENT POINT FOR THE PART. IF YOU NEED TO OBTAIN MORE INFORMATION,
PLEASE CALL YOUR NEAREST SERVICE CENTER, OR
ANY REPLACEMENT PART THAT IS EQUIVALENT IN CHECK PLEASE ZENOAH WEB SITE http://
PERFORMANCE AND DULABILITY MAY BE USED IN www.zenoah.net
NON-WARRANTY MAINTENANCE OR REPAIRS, AND

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