Echo CS-500ES Service Data

01-50D-01

CS-500ES

SERVICE DATA

CHAIN SAW

1

0

ECHO:

CS-500ES

STAGE MODEL

(Serial number : 37000001 and after)

INTRODUCTION

We are constantly working on technical im­provement of our products. For this reason,
technical data, equipment and design are
subject to change without notice. All speci­fications and directions in this SERVICE
DATA are based on the latest product infor­mation available at the time of publication.

CONTENTS

1 SERVICE INFORMATION

1-1 Specifi cation ............................................... 2

1-2 Technical data ............................................. 3

1-3 Torque limits................................................ 4

1-4 Special repairing materials ......................... 4

1-5 Service limits............................................... 5

1-6 Special tools ............................................... 6

2 CARBURETTOR ADJUSTMENT PROCEDURE

2-1 General adjusting rules ............................... 7

2-2 Presetting Idle adjust screw, L mixture needle

and H mixture needle ........................................ 7

2-3 Adjusting carburettor................................... 8

.............................. 2

page

.. 7

3 SERVICE HINT for PET-9000

Reference No.

REVISED: 201201

........................ 8

01-50D-01

ISSUED: 201106

2

1 SERVICE INFORMATION

1-1 Specifi cations

Model CS-500ES

Dimensions Length* mm(in) 395 (15.55)

Width mm(in) 250 (9.84)

Height mm(in) 290 (11.42)

Dry weight* kg(lb) 4.8 (10.5)

Engine Type YAMABIKO, air-cooled, two-stroke, single cylinder

Rotation Clockwise as viewed from the output end

Displacement cm

Bore mm(in) 44.0 (1.732)

Stroke mm(in) 33.0 (1.299)

Compression ratio 7.8

Carburettor Type Diaphragm horizontal-draught

Model

Venturi size-Throttle bore mm(in) 13.5-15.85 (0.531-0.624)

Ignition Type CDI (Capacitor discharge ignition) system

Spark plug BPMR8Y

Starter Type ES (effortless)-start

Rope diameter x length mm(in) 3.8 x 750 (0.150 x 29.5)

Fuel Type Premixed two-stroke fuel

Mixture ratio 50 : 1 (2 %)

Petrol Minimum 89 octane gasoline

Two-stroke air cooled engine oi

Tank capacity L (U.S.fl .oz.) 0.49 (16.6)

Exhaust Muffl er type Spark arrester muf

Clutch Type Centrifugal type

Guide bar / Saw chain lubrication type Adjustable automatic oil pump

Oil Tank capacity L (U.S.

Auto oiler Type Clutch related type

Sprocket Type Floating rim

Number of teeth 7

Pitch in 0.325

* Without guide bar and saw chain.

SERVICE INFORMATION

3

(in3) 50.2 (3.063)

Walbro WT-1011 with Large D-shaped mixture needles

l

fl .oz.) 0.28 (9.5)

ISO-L-EGD (ISO/CD13738), JASO FC/FD

CS-500ES

Digital magneto

fl er

Cutting devices

Guide bar

Saw chain

Part No. 38RV58-325 45RV58-325 50RV58-325

Called length cm 38 45 50

Gauge in 0.058

Type Oregon 21BPX, Carlton K2L
Number of drive links 64 72 80
Pitch in 0.325

Gauge in 0.058

CS-500ES

1-2 Technical data

Engine

Idling speed r/min

Wide open throttle speed* r/min 11,800 - 12,500
Clutch engagement speed r/min 3,900

Engagement Minimum

Compression pressure MPa (kgf/cm

Ignition system

Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1,000 r/min kV 14
Primary coil resistance

(Red Probe on stop terminal of module)

Secondary coil resistance kΩ 2.5 - 2.9
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing at 3,000 r/min °BTDC 17

PET-9000 Parameter 1 324

Carburettor

Idle adjust screw initial setting turns in** 2
L mixture needle initial setting turns out 1 1/2
H mixture needle initial setting turns out 3 1/8
Test Pressure, minimum MPa (kgf/cm
Metering lever height mm(in) 1.65 (0.06) lower than diaphragm seat

Chain oil discharge volume

†

at 8,000 r/min °BTDC 29
at 10,000 r/min °BTDC 35

Parameter 2 03

SERVICE INFORMATION

r/min 3,800

2

) (psi) 1.05 (10.7) (152)

Ω 300 - 340

2

) (psi) 0.05 (0.5) (7.0)

mL/min(U.S.fl .oz./min)

3,100 + 400

- 300

Factory set: 7 mL/min

3

BTDC: Before top dead centre.
* With 45 cm guide bar and properly adjusted saw chain.

**Set idle adjust screw to the point that its tip contacts throttle plate before initial setting.

†

If clutch engagement speed is lower than minimum r/min, replace clutch assembly with new one.

4

1-3 Torque limits

Descriptions

Starter Starter pawl assembly M5 90-120 9-12 80-105
system

Ignition Magneto rotor (Flywheel) M8 150-170 15-17 130-150
system

Ignition switch M 10 20 - 30 2 - 3 18 - 25
Spark plug M 14 130 - 170 13 - 17 113 - 150

Fuel

Carburettor M 5 20 - 30 2 - 3 18 - 25

system

Clutch Clutch shoe LM 10 280 - 300 28 - 30 245 - 265
Clutch drum M 8 150 - 170 15 - 17 130 - 150
Engine Crankcase M 5 70 - 90 7 - 9 60 - 80
Muffl er M 5 70 - 90 7 - 9 60 - 80
Cylinder M 5 70 - 90 7 - 9 60 - 80
Cylinder cover M 5 25 - 35 2.5 - 3.5 22 - 30
Others Auto-oiler M 4 30 - 45 3 - 4.5 25 - 40
Oiler cover M 4 30 - 45 3 - 4.5 25 - 40
Crankcase (at oil bypass) M 5 55 - 70 5.5 - 7 48 - 60
Cushion M 5 20 - 30 2 - 3 18 - 25
Front handle M 5 40 - 55 4 - 5.5 35 - 48
M 4 30 - 45 3 - 4.5 25 - 40
Rear handle assembly
(M side) M 5 40 - 55 4 - 5.5 35 - 48
(D side) M 5 40 - 55 4 - 5.5 35 - 48
Handle lid M 4 20 - 30 2 - 3 18 - 25
Brake lever (D side) M 5 40 - 60 4 - 6 35 - 40
(M side) M 5 50 - 70 5 - 7 45 - 60
Brake cover M 4 10 - 20 1 - 2 9 - 18
Washer (at brake band) M 4 15 - 25 1.5 - 2.5 13 - 22
Sprocket guard plate M 4 15 - 25 1.5 - 2.5 13 - 22
Chain catcher M 5 50 - 70 5 - 7 45 - 60
Spike M 5 50 - 70 5 - 7 45 - 60
Regular bolt, nut and screw M 3 6 - 10 0.6 - 1 5 - 9

M 5 25 - 45 2.5 - 4.5 22 - 40
M 6 45 - 75 4.5 - 7.5 40 - 65

Starter case M5 20-30 2-3 18-25

Ignition coil M 4 30 - 45 3 - 4.5 25 - 40

Elbow M 4 20 - 30 2 - 3 18 - 25

Intake insulator M 4 20 - 30 2 - 3 18 - 20

M 4 15 - 25 1.5 - 2.5 13 - 22

SERVICE INFORMATION

Size

kgf•cm

N•m

CS-500ES

in•lbf

LM: Left-hand thread

1-4 Special repairing materials

Material Location Remarks
Adhesive Cushion Loctite #406 (424) or equivalent
Grease Auto-oiler worm

Clutch needle bearing
Choke knob
Oil seal inner lips
Chain brake (metal contact part)
Throttle rod
Bevel gear, Screw, Chain tensioner

Lithium based grease
Protection

TM

Lubricant

or ECHO XTended

CS-500ES

SERVICE INFORMATION

1-5 Service Limits

ABCD

5K177 5K083 5K084 5K081

E

FGH

5

5K082 5K016 5K025

5K178

KLMP

N

5K173

5K174

5K190

5K097

5K097

Description mm (in)

A Cylinder bore When plating is worn and aluminum can be seen

B

Piston outer diameter Min. 43. 87 (1.727)

C

Piston pin bore Max. 11. 025 (0.4341)

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. 8 (0.03)

K

Con-rod small end bore Max. 15. 025 (0.5915)

L

Crankshaft runout Max. 0. 02 (0.001)

M

Sprocket bore Max. 12. 75 (0.5020)

N

Clutch drum bore Max. 73. 5 (2.89)

P

Sprocket wear limit Max. 0. 5 (0.02)

6

1-6 Special tools

1

SERVICE INFORMATION

2

34

CS-500ES

5

PET-304

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Air Gap Gauge

#.014 = .35mm

Ignition

P/N 91004

9

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Key Part Number Description Reference

1 G310-000050 Tachometer PET-304 Measuring engine speed

2 X605-000050 Torx L wrench Removing and installing bolt

3 897501-03938 Puller Removing magneto rotor

4 897505-16133 Clutch tool Removing and assembling clutch assembly

5 91004 Module air gap gauge Adjusting pole shoe air gaps

6 91037 Compression gauge Measuring cylinder compression

7 897702-30131 Piston pin tool Removing and installing piston pin

8 897701-06030 Bearing wedge Removing and crankshaft ball bearings

9 897563-19830 Metering lever gauge Measuring metering lever height on carburettor

10 X686-000000 ThreeBond 1207D Applying crankcase seam

11 900300

Ignition Analyzer : PET-9000

Measuring Ignition timing, Primary/Secondary voltage

12 897726-21430 Oil seal tool Installing oil seals and clutch plate

13 897800-79931 Spark tester Checking ignition system

14 897803-30133 Pressure tester Testing carburettor and crankcase leakage

15 Y089-000090 D-shaped tool Adjusting mixture needle

16 500-500 Welch plug tool Removing and installing welch plug tool

CS-500ES

1

7

4

3

2

2 CARBURETTOR ADJUSTMENT PROCEDURE

2-1 General adjusting rules

A. Before adjustment, check the following items.

1. The correct spark plug must be clean and properly gapped.

2. The air fi lter element must be clean and properly installed.

3. The muffl er exhaust port must be clear of carbon.

4. The fuel lines, tank vent and fuel fi lter are in good condition and clear of debris.

5. The fuel is fresh ( > 89 octane : RON ) and properly mixed at 50 : 1 with “ISO L-EGD” or “JASO FC/
FD” 2-stroke oil.

6. The recommended bar and chain must be installed, and properly tensioned.

SERVICE INFORMATION

7

NOTE :

should be installed on the unit, otherwise serious engine damage will occur due to overspeeding.

B. Preliminary adjustment. Adjustment by Idle adjust screw of carburettor.
Start and run engine for 100 seconds alternating engine speed between WOT and idle every 5 seconds.

Adjust idle adjust screw to 3,200 +/- 200 r/min. Make sure WOT engine speed in range 11,800 - 12,500
r/min. If engine does not run correctly after this adjustment, proceed to the next step 2-2.

2-2 Presetting Idle adjust screw, L mixture needle and H mixture needle

In order to achieve proper carburettor adjustment, a 38, 45 or 50 cm bar and chain combination

(D)

(B)

(C)

(A)

Tools Required: Small screwdriver with 2.5 mm
blade, P/N G310-000050 electronic tachometer,
P/N Y089-000090 D-Shaped tool (A).

1. Turn L and H mixture needles clockwise until
lightly seated, and then turn out both mixture nee­dles following turns:

L mixture needle (B) : 1 1/2,

H mixture needle (C) : 3 1/8

NOTE:

damage to carburettor may occur.

2. Remove air cleaner lid and air fi lter to expose
the Idle adjust screw and throttle plate. Turn Idle
adjust screw (D) anticlockwise until Idle adjust
screw tip just touches throttle plate. Then turn Idle
adjust screw (D) 2 turns clockwise. Reinstall air fi l-
ter, and cleaner lid.

If needles are overtighted during seating,

NOTE :

adjust screw, L and H mixture needles are intended
to start and run the engine before fi nal carburettor
adjustments are made through this procedure.
The actual number of turns needed for engine
operation may vary.

The initial carburettor settings for Idle

8

2-3 Adjusting carburettor

(D)

(B)

SERVICE INFORMATION

Start and warm engine for 100 seconds alternating

1.
engine speed between WOT and idle every 5 seconds.
Turn H mixture needle (C) anticlockwise until engine
speed drops to approx. 11,400 r/min at WOT.

NOTE :

(C)

(E)

load longer than 10 seconds, or engine damage
may occur.

2. Adjust L mixture needle (B) using D-shaped tool
(A) to reach maximum engine speed just before
lean drop off.

3. Set idle speed to 3,500 r/min by turning Idle
adjust screw (D). Engine speed should be stable
at 3,500 +/- 50 r/min after Idle adjust screw
adjustment.

4. Turn L mixture needle (B) anticlockwise reduc­ing engine idle speed 600 r/min to set idle speed at
2,900 r/min. The engine idle speed ranges is 2,800

- 3,000 r/min.

NOTE :

a minimum of 20 seconds after each adjustment
of L mixture needle to assure accurate tachometer
readings.

CS-500ES

Do not run engine at high speed without

Engine speed must be allowed to stabilize

NOTE :

pulse pipe (E) as shown.

5. Before adjustment, WOT engine speed should be 11,400 r/min or less. If engine speed is higher, turn
H mixture needle (C) anticlockwise until 11,400 r/min is achieved. To make the fi nal WOT engine speed
adjustment, turn H mixture needle (C) clockwise in 1/8 turn increments with the engine at idle, then
squeeze throttle trigger and check WOT engine speed. The fi nal WOT engine speed should fall within
11,800 - 12,000 r/min.

6. Start engine, and verify engine idle speed ranges from 2,800 to 3,500 r/min, and WOT engine speed
ranges from 11,800 to 12,500 r/min. Make sure the chain does not rotate when engine is idling. When
fi nal adjustment is completed, the engine should idle, accelerate smoothly, and attain WOT per above
specifi cations.

NOTE :

to changing ambient conditions, fuel, and engine loads. Engine speed variances should be within the safe
ranges for WOT and Idling speed as listed in Section 1-2 Technical data, otherwise the carburetor should
be readjusted.

3 SERVICE HINT for PET-9000

Engine WOT, and idle speed in fi eld operation may vary from fi nal adjustment specifi cations due

Remove starter and connect red probe (A) of PET­9000 when measuring Ignition timing as shown.

Reinstall starter to start engine.

If you want make sure idle rich size, pinch

(A)

(A)