Echo CS-8002 User Manual

CS-800101-81B-00

INDEX

0 1 2 3

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 products information available at the time of publication. ECHO SERVICE MANUAL Ord. 401-17 (Model : CS-4000, CS-4100, CS-4500, CS4600, CS-5500, CS-6700, CS-8000) and Ord. 401-23 (Model : CS-6702) contains lots of information for servicing this model.

CONTENTS

page

1 SERVICE INFORMATION .............................2

1-1 Specification...............................................2

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

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

1-4 Special repairing materials ........................5

1-5 Service limits..............................................6

1-6 Special tools...............................................7

2 EMISSION ADJUSTMENT GUIDE ............... 8

2-1 General adjusting rules .............................. 8

2-2 Presetting idle adjust screw, L mixture needle

and H mixture needle....................................... 8

2-3 Adjusting carburettor..................................9

Reference No. 01-81B-00

ISSUED: 200411

1 SERVICE INFORMATION

1-1 Specifications

Dimensions Length* mm(in) 421 (16.58)

Width mm(in) 244 (9.61)

Height mm(in) 311 (12.24) Dry weight* kg(lb) 7.5 (16.5) Engine Type KIORITZ, air-cooled, two-stroke, single cylinder

Rotation Clockwise as viewed from the output end

Displacement cm3(in3) 80.7 (4.924)

Bore mm(in) 52.0 (2.047)

Stroke mm(in) 38.0 (1.496)

Compression ratio 7.3 Carburettor Type Diaphragm horizontal-draught

Model Walbro HDA-153B

Venturi size-Throttle bore mm(in) 15.88 - 19 (0.625 - 0.748) Ignition Type CDI (Capacitor discharge ignition) system

Spark plug RCJ-6Y Starter Type Automatic rewind

Rope diameter x length mm(in) 4.0 x 900 (0.16 x 35.4) Fuel Type Premixed two-stroke fuel

Mixture ratio 50 : 1 (2 %) Petrol Minimum 89 octane petrol (RON) Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC

Tank capacity L (U.S.fl.oz.) 0.82 (27.7) Clutch Type Centrifugal, 3-shoe slide Guide bar / Saw chain lubrication type Automatic with volume adjuster and manual

Tank capacity, oil L (U.S.fl.oz.) 0.40 (13.5) Sprocket Type Floating rim

Number of teeth 7

Pitch in 3/8 Guide bar Type for gauge 0.050 in 40RS50-3/8E1 50RS50-3/8E1 60RS50-3/8E1 ---

for gauge 0.058 in 40RS58-3/8E 50RS58-3/8E 60RS58-3/8E 70RS58-3/8E

Called length cm 40 50 60 70 Gauge in 0.050/0.058

Saw chain Number of drive links 60 72 84 96

Pitch in 3/8 Gauge in 0.050/0.058

* Without guide bar and saw chain.

SERVICE INFORMATION CS-8001

Ventilated piston

with electronic timing advancer

40S50 50S50 60S50 ---

40S58 50S58 60S58 70S58

SERVICE INFORMATIONCS-8001

1-2 Technical data

Engine

Idling speed r/min 2300 - 3300 Operating speed r/min 9000 - 9500 Wide open throttle speed* r/min 11500 - 12500 Clutch engagement speed r/min 3500 - 4000 Compression pressure MPa (kgf/cm2) (psi) 0.98 (10.0) (142)

Ignition system

Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028) Minimum secondary voltage at 800 r/min kV 15 Secondary coil resistance kΩ 1.8 - 2.2 Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016) Ignition timing at 1200 r/min °BTDC 10

at 3000 r/min °BTDC 14.5 at 10000 r/min °BTDC 25

Carburettor

Idle adjust screw initial setting turn in** 2 L mixture needle initial setting turns back 2 3/8 H mixture needle initial setting turns back 3 3/8 Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0) Metering lever height mm(in) Flush with diaphragm seat

Chain oil discharge volume at 7000 r/ min Adjustable: 3 - 13 (0.09 - 0.39)

mL/min(U.S.fl.oz./min) (Factory set 8mL/min)

BTDC: Before top dead centre.

*With 50cm guide bar and saw chain. **Set idle adjust screw to contact throttle plate before initial setting.

1-3 Torque limits

Descriptions Size kgf•cm N•m in•lbf Starter Starter center post screw M5* 70 - 110 7 - 11 60 - 95

system

Ignition Magneto rotor (Flywheel) M8 230 - 270 23 - 27 200 - 240 system

Fuel Carburettor M5 50 - 60 5 - 6 45 - 50 system

Clutch Clutch hub LM10 450 - 550 45 - 55 390 - 480 Engine Crankcase M5*

Others Cushion Crankcase M4 35 - 50 3.5 - 5.0 35 - 45

Regular bolt, nut, M3 6 - 10 0.6 - 1.0 5 - 9 and screw

Starter pawl M5* 70 - 110 7 - 11 60 - 95 Starter case M5 50 - 60 5 - 6 45 - 50

Ignition coil M4 35 - 50 3.5 - 5.0 30 - 45 Spark plug M14 150 - 170 15 - 17 130 - 150

Carburettor case M5 30 - 45 3.0 - 4.5 26 - 40

Cylinder M6 Cylinder cover M5 50 - 60 5 - 6 45 - 50 Muffler M5 100 - 130 10 - 13 90 - 110

Carburettor case M5 25 - 50 2.5 - 5.0 22 - 45 Rear handle M5 30 - 45 3.0 - 4.5 26 - 40 Auto-oiler M4 35 - 50 3.5 - 5.0 30 - 45 Manual oiler M5 35 - 60 3.5 - 6.0 30 - 50 Throttle latch M4 6 - 10 0.6 - 1.0 5 - 9 Handle assembly M5 70 - 110 7 - 11 60 - 95 Brake lever (Hand guard) M5 25 - 45 2.5 - 4.5 22 - 40 Chain catcher M5 30 - 45 3.0 - 4.5 26 - 40 Chain brake adjuster M5 30 - 45 3.0 - 4.5 26 - 40 Guide bar M8 200 - 230 20 - 23 175 - 200 Sprocket guard plate M3 6 - 10 0.6 - 1.0 5 - 9

SERVICE INFORMATION CS-8001

†

M4 15 - 25 1.5 - 2.5 13 - 22 M5 25 - 45 2.5 - 4.5 22 - 40 M6 45 - 75 4.5 - 7.5 40 - 65

70 - 110 7 - 11 60 - 95

130 - 190 13 - 19 110 - 170

LM: Left-hand thread *Apply thread locking sealant (See next page)

†

The torque differences among four bolts should not exceed 20 kgf• cm (2Nm, 17in•lbf) on one cylinder or

crankcase.

SERVICE INFORMATIONCS-8001

1-4 Special repairing materials

Material Location Remarks Adhesive Stud bolt

Bellows holder Intake insulator Cushion (Rear handle) Check valve assembly

Thread locking sealant Starter pawl screws Loctite #242, ThreeBond 1324 or equivalent

Stater center post screws Brake adjuster screws Loctite #222, ThreeBond 1342 or equivalent Throttle bearing screws

Grease Auto-oiler worm

Clutch needle bearing Cushion inside Rewind spring Lithium based grease Oil seal lip Choke knob Brake seal Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)

Loctite #609, ThreeBond 1373 or equivalent

Loctite #406 (424), ThreeBond 1741 or equivalent

SERVICE INFORMATION CS-8001

1-5 Service Limits

ABCD

5K171

5K083 5K084 5K081

EFGH

5K082 5K016 5K042 5K172

KLMP

5K173 5K175 5K171 5K097

Description mm (in) A Cylinder bore When plating is worn and aluminium can be seen B Piston outer diameter Min. 51.82 (2.040) C Piston pin bore Max. 13.020 (0.5126) D Piston ring groove Max. 1.3 (0.051) E Piston ring side clearance Max. 0.1 (0.004) F Piston pin outer diameter Min. 12.980 (0.5110) G Piston ring width Min. 1.15 (0.045) H Piston ring end gap Max. 0.5 (0.02) K Con-rod small end bore Max. 17.025 (0.6703) L Crankshaft runout Max. 0.05 (0.002) M Sprocket bore Max. 18.02 (0.712) N Clutch drum bore Max. 79.0 (3.11) P Sprocket wear limit Max. 0.5 (0.02)

120

140

160

180

100

1-6 Special tools

a = 4 mm a = 5 mm

SERVICE INFORMATIONCS-8001

14 15

b = 3 mm b = 4 mm b = 5 mm

17 18

Key Part Number Description Used for:

1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor 2 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolt (M5) 3 895611-79920 L-hex wrench (5 mm) Removing and installing hex. socket bolt (M6) 4 897500-00335 Puller Removing auto oiler oil cover 5 897501-03938 Puller Removing magneto rotor 6 897502-19830 Crankcase tool Separating crankcase 7 897505-16133 Clutch tool Removing and installing clutch assembly 8 897537-30130 Piston stopper Locking crankshaft rotation 9 897701-14732 Bearing tool Removing and installing ball bearings on crankcase

10 897702-30131 Piston pin tool Removing and installing piston pin

11 897708-19835 Worm puller Removing auto-oiler worm 12 Y089-000010 Worm inserter Installing auto-oiler worm 13 897719-02830 Piston holder Making piston steady remove and install piston / rings 14 897724-01261 Spring pin tool (3 mm) Removing and installing spring pin (3 mm dia) 15 897724-01361 Spring pin tool (4 mm) Removing and installing spring pin (4 mm dia) 16 897724-02831 Spring pin tool (5 mm) Removing and installing spring pin (5 mm dia) 17 897726-21430 Oil seal tool Installing starter side oil seal 18 897727-19830 Oil seal tool Installing clutch side oil seal 19 897740-19830 Cushion tool Removing and installing cushion (Right - Rear - Upper) 20 897800-79931 Spark tester Checking ignition system 21 897803-30130 Pressure tester Testing carburettor and crankcase leakage 22 897827-16131 Pressure plate Plugging intake port to test crankcase / cylinder leakages 23 91007 Compression gauge Measuring cylinder compression

2 EMISSION ADJUSTMENT GUIDE

2-1 General adjusting rules

Before starting the unit for adjustment, check the following items.

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

2. The air filter element must be clean and properly installed.

3. The muffler exhaust port must be clear of carbon.

4. The fuel lines, tank vent and fuel filter 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” 2-stroke oil.

6. The recommended bar and chain must be installed to the power head, and properly tensioned. NOTE : Make sure of proper installation of 50cm guide bar and saw chain when adjusting carburettor, or

serious engine damage will occur due to overspeeding.

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

SERVICE INFORMATION CS-8001

1. Take off plug (C) for adjusting L and H mixture needle. Turn the L and H mixture needles out anticlockwise to rich stop, and meet limiter caps tabs (A) with locating slots (B).

idle adjust screw

(C)

(B)

(A)

(B)

2. Screw 2.5 mm wood screw in the center of the L limiter cap.

NOTE : Screw the wood screw in until it lightly contacts L mixture needle in the cap.

3. Pull the wood screw with limiter cap using pliers.

4. Repeat Step 2 and Step 3 for H limiter cap removal.

5. Turn L and H mixture needle clockwise lightly seated. and then turn out both needles following turns.

L mixture needle : 2 3/8, H mixture needles : 3 3/8 NOTE : If needles are forced during seating, damage

to carburettor may occur.

6. Turn idle adjust screw anticlockwise and set the screw until the tip to just contact throttle plate. Then turn idle adjust screw 2 turns clockwise.

2-3 Adjusting carburettor

SERVICE INFORMATIONCS-8001

idle adjust screw

1. Start engine and warm it up well for 2 -3 minutes with cycle of 5 seconds at WOT (Wide Open Throttle) and 10 seconds at idling.

2. Using 2.5 mm wide blade screw driver, adjust L mixture needle to obtain maximum idle speed.

3. Set idle speed to 3,000 r/min by turning idle adjust screw (in the range of 2,700 to 3,300 r/min allowable).

4. Turn L mixture needle anticlockwise to reduce engine idle speed 500 r/min to set idle speed in the range of 2,200 to 2,800 r/min.

NOTE : Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings.

5. Turn H mixture needle anticlockwise at WOT until engine speed drops less than 11,000 r/min.

6. Adjust WOT engine speed in the range of 11,500 to 12,500 r/min by turning H mixture needle clockwise.

NOTE : During H mixture needle adjustment, do not run engine at high speed without load longer than 5 seconds.

7. If the engine speed at WOT is above 12,500 r/min, adjust H mixture needle anticlockwise and set maximum engine speed at less than 12,500 r/min.

8. After adjusting carburettor, put the limiter cap on the tip of 2.5 mm wood screw and install the caps on L and H mixture needles.

NOTE : Align the limiter caps tabs (A) with locating slots (B) in extended housing of carburettor.

(B)

(A)

9. Tap the respective limiter caps in as shown.

10. Start engine again and make it sure engine runs at idle speed in the range of 2,300 to 3,300 r/min and at WOT engine speed in the range of 11,500 to 12,500 r/min. Also make it sure chain would not turn at engine idle speed and suitable acceleration.

(B)

2-3 Adjusting carburettor

SERVICE INFORMATIONCS-8001

1. Start engine and warm it up well for 2 -3 minutes with cycle of 5 seconds at WOT (Wide Open Throttle) and 10 seconds at idling.

2. Using 2.5 mm wide blade screw driver, adjust L mixture needle to obtain maximum idle speed.

3. Set idle speed to 3,000 r/min by turning idle adjust screw (in the range of 2,700 to 3,300 r/min allowable).

4. Turn L mixture needle anticlockwise to reduce engine idle speed 500 r/min to set idle speed in the range of 2,200 to 2,800 r/min.

NOTE : Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings.

5. Turn H mixture needle anticlockwise at WOT until engine speed drops less than 11,000 r/min.

(B)

(A)

6. Adjust WOT engine speed in the range of 11,500 to 12,500 r/min by turning H mixture needle clockwise.

NOTE : During H mixture needle adjustment, do not run engine at high speed without load longer than 5 seconds.

7. If the engine speed at WOT is above 12,500 r/min, adjust H mixture needle anticlockwise and set maximum engine speed at less than 12,500 r/min.

8. After adjusting carburettor, put the limiter cap on

(A)

(B)

the tip of 2.5 mm wood screw and install the caps on L and H mixture needles.

NOTE : Align the limiter caps tabs (A) with locating slots (B) in extended housing of carburettor.

9. Tap the respective limiter caps in as shown.

NOTE : Initial carburettor setting (Idle adjust screw, L and H mixture needles) shown here is to start the engine after restoration or carburettor change. Idle adjust screw, L and H needles turn for designated engine revolution through procedures indicated here may vary . As long as idle and WOT engine speed is set in given range, variance would be ignorable.

Echo CS-8002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual