Group 32 Gate 4

Gate 4: Critical Design Review

Reassembly Process

Step	Tool Used	Part Removed	Location on Product	Time it Took	Ease Rating 1-5	Directions
1	None	Crank Shaft, Piston, and Rod	Inside Crank Casing and Protruding from Both Sides	30 sec	2	Insert the parts back into the crankcase.
2	Vice Grips, 15/16" Crescent Wrench, and Leverage Bar	Clutch Assembly	Attached to Crank Shaft on Opposite Side of Casing From Piston and Rod	5 min	5	Clamp the vice grips to the crank case in a position that will prevent the counter balance to pass it therefore keeping the crank shaft from spinning freely. Put the open end of the crescent wrench in the slots on the clutch and using a leverage bar in the other end of the wrench,twist in the direction opposite of the arrow (reverse threaded) and tighten the clutch on.
3	None	Throttle and "Cable"	Inside the handle part of the casing	1 sec	1	Set the trigger onto shaft according to the picture.
4	Straight Blade Screw Driver	Left Half of the Casing	Exterior	5 min	2	Screw in all 7 bolts holding the two sides of the casing together.
5	Straight Blade Screw Driver	Timing Mechanism	Under the timing mechanism cover	5 sec	2	Bolt the timing mechanism back on. (*Make sure the contact trigger barely makes contact with the sensor to result in the right timing.)
6	None	Plastic Holder	Next to Crank Shaft	.5 sec	1	Insert the plastic holder back in it's slot.
7	Straight Blade Screw Driver	Battery	Next to Crank Shaft, Under Flywheel	10 sec	2	Screw the battery back in with the two bolts.
8	14 mm Crescent Wrench	Cylinder	Surrounding Piston and Rod, Beneath Intake	5 min	3	Bolt the cylinder back on. Make sure the piston ring is compressed and the piston goes in straight. Also, check to make sure the intake port lines up with the casing.
9	Straight Blade Screw Driver	Intake	Top, Under Intake Cover	10 sec	2	Slide the intake in, bolt it on, and connect the fuel line.
10	Straight Blade Screw Driver	Choke	Connected to Intake	15 sec	3	Insert the tab on the end of the choke onto the intake.
11	Straight Blade Screw Driver	Spark Plug Timing Mechanism Cover	Above Timing Mechanism	3 sec	2	Place the cover back on and insert the clip onto the copper shaft.
12	14 mm Socket & 1/4" Drive	Fly Wheel	Under Fly Wheel Cover	30 sec	2	Bolt the flywheel back on to the crankshaft.
13	Straight Blade Screw Driver	Magneto and Spark Plug Wire	Beside the Fly Wheel	15 sec	3	Bolt the magneto back on. Make sure the magneto is as close to the flywheel as possible, but not touching it. Spin the flywheel a couple times to test the clearance.
14	Straight Blade Screw Driver	Exhaust Header	Under Muffler/Exhaust Cover	30 sec	2	Screw the three bolts back on.
15	Straight Blade Screw Driver	Muffler/Exhaust Cover	Side, Next to Clutch	30 sec	2	Reattach the exhaust using the three bolts removed.
16	crescent wrench	On/Off Switch	Attached to Bottom Cover	5 sec	2	Slide the switch back into the bottom casing, and screw the thin hex nut back on.
17	Straight Blade Screw Driver	Bottom Exterior Cover	Bottom	1 min	2	Bolt the cover back on using the four bolts. Leave the lower left (looking at the chainsaw from the user's view) bolt off.
18	Straight Blade Screw Driver	Flywheel Cover	Exterior	1 min	2	Bolt the cover back on using 3 bolts.
19	Straight Blade Screw Driver	Handle	Exterior	1 min	2	Bolt the handle back on using the four bolts, nuts and washers.
20	None	Chain Bar	In between Clutch and Body	1 sec	1	Slide the bar back onto the bolts and the bolt that adjusts the chain tension.
21	14 mm Socket & 1/4" Drive	Clutch Cover	Exterior	30 sec	2	Bolt the cover back on with the two washers and nuts.
22	Straight Blade Screw Driver	Intake Cover Locking	Underneath Intake Cover	5 sec	2	Attach it using a single bolt.
23	Straight Blade Screw Driver	Intake Cover	Exterior	5 sec	2	Place the cover over the intake, push the screw in and turn it 90 degrees.

The Difficulty Scale is rated accordingly:

• 1 = No tool required
• 2 = One tool required with little force required
• 3 = One tool required with a large force or accuracy required
• 4 = Multiple or specialized tools required with little force required
• 5 = Multiple or specialized tools required with a large force or accuracy required

Final Assessment

Does your product run the same as it did before you disassembled it?

The product still does not work. The pull start still gets jammed and slowly recoils, and the engine needs replacement parts in order to be repaired. Also, there is a hole in the crankcase preventing the chainsaw from ever working.

What were the differences between the disassembly and the reassembly processes?

During reassembly the same tools were used, however there is more detailed work required to make the chainsaw work. This includes a miniscule distance between the magneto and the flywheel, The timing of the spark plug must be accurately positioned, and the carberator must be tuned according to the manual. Overall we were able to reassembly the chainsaw with no problems.

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