Echo CS-8001 Series Montageanleitung

CS-800101-81B-00 1

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, CS-

4600, 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

INDEX

SERVICE INFORMATION CS-8001

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

Ventilated piston

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

with electronic timing advancer

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 ---

40S50 50S50 60S50 ---

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

40S58 50S58 60S58 70S58

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 INFORMATIONCS-8001 3

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 kΩ1.8 - 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.

SERVICE INFORMATION CS-8001

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 Starter pawl M5* 70 - 110 7 - 11 60 - 95

Starter case M5 50 - 60 5 - 6 45 - 50

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

system Ignition coil M4 35 - 50 3.5 - 5.0 30 - 45

Spark plug M14 150 - 170 15 - 17 130 - 150

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

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

Clutch Clutch hub LM10 450 - 550 45 - 55 390 - 480

Engine Crankcase M5*†70 - 110 7 - 11 60 - 95

Cylinder M6†130 - 190 13 - 19 110 - 170

Cylinder cover M5 50 - 60 5 - 6 45 - 50

Muffler M5 100 - 130 10 - 13 90 - 110

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

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

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

and screw 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

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 5

1-4 Special repairing materials

Material Location Remarks

Adhesive Stud bolt Loctite #609, ThreeBond 1373 or equivalent

Bellows holder

Intake insulator Loctite #406 (424), ThreeBond 1741

Cushion (Rear handle) or equivalent

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)

SERVICE INFORMATION CS-8001

123

45678910 11

5K083 5K084 5K081

5K082 5K016 5K042 5K172

5K173 5K175 5K171 5K097

5K171

1-5 Service Limits

ABCD

EFGH

KLMP

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)

SERVICE INFORMATIONCS-8001 7

120

140

160

180

100

1-6 Special tools

811

12 13 15 17 18

19 21

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

a = 4 mm

a = 5 mm

b = 3 mm

b = 4 mm

b = 5 mm

SERVICE INFORMATION CS-8001

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

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).

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.

idle adjust screw

(C)

(A)

(B)

(A)

SERVICE INFORMATIONCS-8001 9

2-3 Adjusting carburettor

1. Start engine and warm it up well for 2 -3 minutes

with cycle of 5 seconds at WOT (Wide OpenThrottle)

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

to12,500 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.

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.

idle adjust screw

(A)

(B)

(A)

SERVICE INFORMATIONCS-8001 9

2-3 Adjusting carburettor

1. Start engine and warm it up well for 2 -3 minutes

with cycle of 5 seconds at WOT (Wide OpenThrottle)

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

to12,500 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.

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.

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.

(A)

(B)

(A)

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