Echo CS-500ES Montageanleitung

CS-500ES

01-50D-01 1

INTRODUCTION

We are constantly working on technical im-

provement of our products. For this reason,

technical data, equipment and design are

subject to change without notice. All speci-

fications and directions in this SERVICE

DATA are based on the latest product infor-

mation available at the time of publication.

SERVICE DATA

CHAIN SAW

ECHO: CS-500ES

STAGE MODEL

(Serial number : 37000001 and after)

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 CARBURETTOR ADJUSTMENT PROCEDURE

.. 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

3 SERVICE HINT for PET-9000........................ 8

Reference No. 01-50D-01

REVISED: 201201

ISSUED: 201106

SERVICE INFORMATION CS-500ES

Cutting devices

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

Called length cm 38 45 50

Gauge in 0.058

Saw chain Type Oregon 21BPX, Carlton K2L

Number of drive links 64 72 80

Pitch in 0.325

Gauge in 0.058

1 SERVICE INFORMATION

1-1 Speciﬁcations

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 cm3(in3) 50.2 (3.063)

Bore mm(in) 44.0 (1.732)

Stroke mm(in) 33.0 (1.299)

Compression ratio 7.8

Carburettor Type Diaphragm horizontal-draught

Model

Walbro WT-1011 with Large D-shaped mixture needles

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

Ignition Type CDI (Capacitor discharge ignition) system

Digital magneto

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

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

Exhaust Mufﬂer type Spark arrester mufﬂer

Clutch Type Centrifugal type

Guide bar / Saw chain lubrication type Adjustable automatic oil pump

Oil Tank capacity L (U.S.ﬂ.oz.) 0.28 (9.5)

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

CS-500ES 3

1-2 Technical data

Engine

Idling speed r/min 3,100 + 400

- 300

Wide open throttle speed* r/min 11,800 - 12,500

Clutch engagement speed r/min 3,900

Engagement Minimum†r/min 3,800

Compression pressure MPa (kgf/cm2) (psi) 1.05 (10.7) (152)

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 Ω300 - 340

(Red Probe on stop terminal of module)

Secondary coil resistance kΩ2.5 - 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

at 8,000 r/min °BTDC 29

at 10,000 r/min °BTDC 35

PET-9000 Parameter 1 324

Parameter 2 03

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/cm2) (psi) 0.05 (0.5) (7.0)

Metering lever height mm(in) 1.65 (0.06) lower than diaphragm seat

Chain oil discharge volume Factory set: 7 mL/min

mL/min(U.S.ﬂ.oz./min)

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.

SERVICE INFORMATION CS-500ES

1-3 Torque limits

Descriptions Size kgf•cm N•m in•lbf

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

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

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

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

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

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

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

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

Mufﬂer 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 4 15 - 25 1.5 - 2.5 13 - 22

M 5 25 - 45 2.5 - 4.5 22 - 40

M 6 45 - 75 4.5 - 7.5 40 - 65

LM: Left-hand thread

1-4 Special repairing materials

Material Location Remarks

Adhesive Cushion Loctite #406 (424) or equivalent

Grease Auto-oiler worm

Lithium based grease

or ECHO XTended

Protection TM

Lubricant

Clutch needle bearing

Choke knob

Oil seal inner lips

Chain brake (metal contact part)

Throttle rod

Bevel gear, Screw, Chain tensioner

SERVICE INFORMATION

CS-500ES 5

1-5 Service Limits

5K177 5K083 5K084 5K081

5K082 5K016 5K025

5K174

5K178

5K173 5K190 5K097

5K097

ABCD

FGH

KLMP

Description mm (in)

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

BPiston outer diameter Min. 43. 87 (1.727)

CPiston pin bore Max. 11. 025 (0.4341)

DPiston ring groove Max. 1. 6 (0.063)

EPiston ring side clearance Max. 0. 1 (0.004)

FPiston pin outer diameter Min. 10. 98 (0.4323)

GPiston ring width Min. 1. 45 (0.057)

HPiston ring end gap Max. 0. 8 (0.03)

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

LCrankshaft runout Max. 0. 02 (0.001)

MSprocket bore Max. 12. 75 (0.5020)

NClutch drum bore Max. 73. 5 (2.89)

PSprocket wear limit Max. 0. 5 (0.02)

SERVICE INFORMATION CS-500ES

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Ignition Air Gap Gauge

#.014 = .35mm

P/N 91004

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PET-304

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1-6 Special tools

134

10 11 1312

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

SERVICE INFORMATION

CS-500ES 7

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 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” or “JASO FC/

FD” 2-stroke oil.

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

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

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

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 nee-

dles following turns:

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

H mixture needle (C) : 3 1/8

NOTE: If needles are overtighted during seating,

damage to carburettor may occur.

2. Remove air cleaner lid and air ﬁlter 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 ﬁl-

ter, and cleaner lid.

NOTE : The initial carburettor settings for Idle

adjust screw, L and H mixture needles are intended

to start and run the engine before ﬁnal carburettor

adjustments are made through this procedure.

The actual number of turns needed for engine

operation may vary.

(A)

(B) (C)

(D)

SERVICE INFORMATION CS-500ES

2-3 Adjusting carburettor

Start and warm engine for 100 seconds alternating

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 : Do not run engine at high speed without

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 reduc-

ing 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 : Engine speed must be allowed to stabilize

a minimum of 20 seconds after each adjustment

of L mixture needle to assure accurate tachometer

readings.

NOTE : If you want make sure idle rich size, pinch

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 ﬁnal 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 ﬁnal 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

ﬁnal adjustment is completed, the engine should idle, accelerate smoothly, and attain WOT per above

speciﬁcations.

NOTE : Engine WOT, and idle speed in ﬁeld operation may vary from ﬁnal adjustment speciﬁcations due

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

Remove starter and connect red probe (A) of PET-

9000 when measuring Ignition timing as shown.

Reinstall starter to start engine.

(B) (C)

(D)

(E)

(A)

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