ES-2100, ES-240021-21G-00
INDEX
1
2
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, illustrations and directions in
this SERVICE DATA are based on the latest
products information available at the time of
publication.
ECHO SERVICE MANUAL Ord. 403-11
(Model : PB-2100, PB-2110, ES-2100, ES-
2400) 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.........................4
1-5 Service limits .............................................. 5
1-6 Special tools...............................................6
2 EMISSION ADJUSTMENT GUIDE ...............7
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
Reference No. 21-21G-00
ISSUED: 200411
ES-2100
2
1 SERVICE INFORMATION
1-1 Specifications
Model ES-2100 ES-2400
Dimensions Length* mm(in) 285 (11.1) 285 (11.3)
Width mm(in) 330 (12.7) 330 (12.9)
Height mm(in) 340 (13.4) 340 (13.4)
Dry weight kg(lb) 4.4(9.7)**, 5.5 (12.1)***
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Anticlockwise as viewed from the output end
Displacement cm3(in3) 21.2 (1.294) 23.6 (1.440)
Bore mm(in) 32.2 (1.268) 34.0 (1.339)
Stroke mm(in) 26.0 (1.024) 26.0 (1.024)
Compression ratio 7.0 6.3
Carburettor Type Diaphragm horizontal-draught with primer (purge bulb)
Model ZAMA C1U-K43B ZAMA C1U-K44B
Venturi size-Throttle bore mm(in) 7 - 14 (0.276 - 0.551) 8 - 14 (0.315 - 0.551)
Ignition Type CDI (Capacitor discharge ignition) system
Spark plug RCJ-7Y
Starter Type Automatic rewind
Rope diameter x length mm(in) 3.0 x 1000 (0.12 x 39.4)
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.) 0.5 (16.9)
Handle Type Rear Grip Rubber Grip
Blower Fan type Centrifugal, single stage
Max. air volume (with pipes)
Max. air velocity (with pipes)
Blower pipe length mm (in) Straight 425 (16.73)
Blower nozzle size, (inner) mm (in) 117 x 26 (4.6 x 1.02) oval shape
Fan head nozzle Standard
Vacuum Shredding knife with
Vacuum pipe ID x L mm(in) 110 x 880 (4.33 x 34.65)
Dust bag capacity liter(ft3) 60 (2.1)
Volume reduction ratio(Leaves) 12
* Without blower pipes
** With fan head nozzle
*** With all blower pipes and suction pipe
SERVICE INFORMATION
m3/min (ft3/min) 7.0 (247.2)** 7.6 (268.4)**
m/s (mph) 65 (145)** 64 (143)**
mm (in) Fan head nozzle 420 (16.54)
ES-2400
ES-2100
ES-2400
1-2 Technical data
Model ES-2100 ES-2400
Engines
Idling speed r/min 2400 - 3200
Wide open throttle speed* r/min 6900 - 8100 7500 - 8800
Compression pressure MPa (kgf/cm2) (psi) 0.72 (7.4) (105) 0.69 (7.0) (100)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1500 r/min kV 16
Secondary coil resistance kΩ 1.2 - 1.8
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing °BTDC 28
Carburettor
Idle adjust screw initial setting turn in** 1 3/8 2 1/2
L mixture needle initial setting turn back 1 1/2 1 1/2
H mixture needle initial setting turn back 1 1/2 1 3/4
Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 0.1 - 0.25 (0.004-0.010) lower than diaphragm seat
SERVICE INFORMATION
3
BTDC: Before top dead centre.
* With all blower pipes.
** Set idle adjust screw to contact throttle plate before initial setting.
ES-2100
4
1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter Starter pawl M8 80 - 100 8 - 10 70 - 85
system
Ignition Ignition coil M4 35 - 50 3.5 - 5.0 30 - 45
system
Fuel Carburettor insulator M5* 25 - 40 2.5 - 4.0 22 - 35
system
Engine Crankcase M5 70 - 110 7 - 11 60 - 95
Others Fan case M5
Regular bolt, nut, M3 6 - 10 0.6 - 1.0 5 - 9
and screw
Starter case M4* 25 - 35 2.5 - 3.5 22 - 30
Spark plug M14 150 - 170 15 - 17 130 - 150
Carburettor M5 35 - 45 3.5 - 4.5 30 - 40
Cylinder M5 70 - 110 7 - 11 60 - 95
Engine mount M4* 35 - 50 3.5 - 5.0 30 - 45
Muffler M5 60 - 100 6 - 10 50 - 85
Fan hub M8* 160 - 200 16 - 20 140 - 175
Fan M8 160 - 200 16 - 20 140 - 175
SERVICE INFORMATION
†
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
M8 110 - 150 11 - 15 95 - 130
30 - 45 3.5 - 4.5 26 - 40
ES-2400
* Apply thread locking sealant (See below)
†
Tapping screw
1-4 Special repairing materials
Material Location Remarks
Thread locking sealant Starter case bolts
Ignition coil
Carburettor insulator screws Loctite #242, ThreeBond 1324 or equivalent
Engine mount
Fan hub
Fan
Grease Rewind spring
Starter center shaft
Lithium based grease
ES-2100
ES-2400
1-5 Service Limits
ABCD
5K193 5K228 5K229 5K230
SERVICE INFORMATION
5
E
5K231 5K016
K
5K171
FGH
5K042 5K194
Description ES-2100 ES-2400
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 32.11 (1.264) 33.91 (1.335)
C Piston pin bore Max. 8.030 (0.3161) 8.030 (0.3161)
D Piston ring groove Max. 1.6 (0.063) 1.6 (0.063)
E Piston ring side clearance Max. 0.1 (0.004) 0.1 (0.004)
F Piston pin outer diameter Min. 7.970 (0.3138) 7.970 (0.3138)
G Piston ring width Min. 1.45 (0.057) 1.45 (0.057)
H Piston ring end gap Max. 0.5 (0.02) 0.5 (0.02)
K Crankshaft runout Max. 0.05 (0.002) 0.05 (0.002)
6
20
40
60
80
120
140
160
180
20
100
1-6 Special tools
SERVICE INFORMATION
ES-2100
ES-2400
1
6
2
7
10 11 1312
80
100
60
120
14 15
40
140
20
160
180
20
3
8
4
5
9
a = 3 mm
a = 4 mm
Key Part Number Description Used for:
1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor
2 363018-00310 Washer Installing crankcase oil seal of starter side
3 433019-12330 Flange nut Removing magneto rotor (flywheel)
4 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolt (M4)
5 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolt (M5)
6 897701-06030 Bearing wedge Removing and crankshaft ball bearings
7 897701-14732 Bearing tool Removing and installing crankcase ball bearings
8 897702-30131 Piston pin tool Removing and installing piston pin
9 897705-11520 Bearing tool Removing and installing con-rod small end needle bearing
10 897714-24330 Oil seal tool Installing oil seals
11 897800-79931 Spark tester Checking ignition system
12 897803-30132 Pressure tester Testing carburettor and crankcase leakage
13 897835-16131 Pressure connector Checking crankcase and cylinder leakages
14 900100-08008 Bolt Removing magneto rotor (flywheel)
15 91007 Compression gauge Measuring cylinder compression
ES-2100
ES-2400
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. All blower pipes are installed for proper engine loading.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
SERVICE INFORMATION
1. Turn L mixture needle clockwise until lean stop
to cut easily.
7
2. Using a sharp knife, give triangle cut between
the stopper wings. Also cut the H limiter cap.
NOTE : Be careful when cutting caps, otherwise
injury may result.
3. Pull the caps off with pliers.
NOTE : Do not rock back and forth when removing,
otherwise the needle may be damaged.
4. Turn H and L mixture needles clockwise until
lightly seated.
NOTE : Do not over tighten needles, otherwise
needles tip and seat damage may occur.
5. Turn L mixture needle anticlockwise 1 1/2 turns.
Turn H mixture needle anticlockwise 1 1/2 turns (ES-
2100), 1 3/4 turns (ES-2400).
6. Turn idle adjust screw anticlockwise and set the
screw until the tip to just contact throttle plate. Then
turn it clockwise 1 3/8 turns (ES-2100), 2 1/2 turns
(ES-2400).
8
2-3 Adjusting carburettor
SERVICE INFORMATION
1. Start engine and warm it up well for about 3 - 5
minutes with cycle of 50 seconds at WOT (Wide
Open Throttle) and 10 seconds at idling.
2. Adjust H mixture needle to obtain maximum
engine speed at WOT. And then turn H mixture
needle clockwise until the engine speed starts to
drop.
3. When the engine speed starts to drop, turn H
mixture needle anticlockwise to obtain maximum
engine speed again. And then turn H mixture needle
anticlockwise further to reduce engine speed 10 to
20 r/min (ES-2100), 30 to 40 r/min (ES-2400) from
maximum engine speed.
4. Adjust the L mixture needle to obtain maximum
idle speed.
5. Set idle speed in the range of 2,950 to 3,050 r/min
by turning idle adjust screw.
ES-2100
ES-2400
6. Turn L mixture needle anticlockwise to reduce
engine idle speed 200 to 300 r/min and set engine
idle speed in the rage of 2,650 to 2,850 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.
7. After adjusting carburettor , install White limiter cap
on L mixture needle and Red limiter cap on H mixture
needle as shown.
NOTE : Before installing limiter caps, warm caps
in 90 °C hot water for smooth installation. Make it
sure to use pliers or appropriate instrument to take
warmed up cap out from the water.
8. Tap respective limiter caps to the bottoms as
shown.
9. Start engine again and make it sure engine runs
in the range of 2,400 to 3,200 r/min at idling and the
range of 6,900 to 8,100 r/min (ES-2100), 7,500 to
8,800 r/min (ES-2400) at WOT. Also make it sure
suitable acceleration.
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