Echo CS-4400 Mounting instructions

CS-4400, CS-510001-44C-01 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, illustrations and directions in
this SERVICE DATA are based on the latest
products information available at the time of
publication.
ECHO SERVICE MANUAL Ord.401-21
(Model:CS-4200,CS-4400) contains lots of
information for servicing this model.
0
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 ............................................... 8
2 EMISSION ADJUSTMENT GUIDE ............... 9
CS-4400
2-1 General adjusting rules .............................. 9
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle ....................................... 9
2-3 Adjusting idle speed and WOT speed ...... 10
CS-5100
2-1 General adjusting rules ............................ 11
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle ..................................... 11
2-3 Adjusting carburettor................................. 12
Reference No. 01-44C-01
REVISED: 200510
INDEX
ISSUED: 200410

SERVICE INFORMATION CS-4400
CS-5100
2
1 SERVICE INFORMATION
1-1 Specifications
Model CS-4400 CS-5100
Dimensions Length* mm(in) 398 (15.7)
Width mm(in) 252 (9.9)
Height mm(in) 272 (10.7)
Dry weight* kg(lb) 4.6 (10.1) 4.9 (10.8)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Rotation Clockwise as viewed from the output end
Displacement cm3(in3) 43.5 (2.654) 49.3 (3.008)
Bore mm(in) 43.0 (1.693) 45.0 (1.772)
Stroke mm(in) 30.0 (1.181) 31.0 (1.220)
Compression ratio 7.6 7.5
Carburettor Type Diaphragm horizontal-draught with auto-return choke
Model Walbro WT-416C ZAMA C1Q-K79
Venturi size-Throttle bore mm(in) 13.5 - 15.85 (0.532 - 0.624) 13.5 - 16 (0.532 - 0.630)
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) 3.5 x 1000 (0.14 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 oilISO-L-EGD (ISO/CD13738), JASO FC
Tank capacity L (U.S.fl.oz.) 0.6 (20.3)
Clutch Type Centrifugal, 3-shoe slide with 3-tension spring
Guide bar / Saw chain lubrication type Automatic with volume adjuster
Oil Tank capacity L (U.S.fl.oz.) 0.28 (9.5)
Sprocket Type Spur Floating rim
Number of teeth 7 7
Pitch in 0.325 0.325
Cutting devices
Guide bar Type (CS-4400) --- 45RV58-325 38RV58-325
(CS-5100) 38RV58-325 45RV58-325 50RV58-325
Called length cm 38 45 50
Gauge in 0.058
Saw chain Number of drive links 56 64 72
Pitch in 0.325
Gauge in 0.058
* Without guide bar and saw chain.

SERVICE INFORMATION
CS-4400
CS-5100 3
1-2 Technical data
Model CS-4400 CS-5100
Engine
Idling speed r/min 2300 - 2800 2300 - 2800
Operating speed* r/min 9500 - 10500 10500 - 11000
High speed (No load full throttle)* r/min 11500 - 13000 12500 - 13500
Clutch engagement speed* r/min 3500 - 4000 3500 - 4000
Compression pressure MPa (kgf/cm2) (psi) 1.05 (10.5) (146) 1.00 (10.2) (145)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage kV 14.5 23.0
(CS-4400 at 800 r/min, CS-5100 at 1500 r/min)
Secondary coil resistance kΩ1.7 - 2.2
Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)
Ignition timing at 800 r/min °BTDC 14.5 ---
at 1500 r/min °BTDC --- 17
at 3000 r/min °BTDC 18.5
at 10000 r/min °BTDC 28
Carburettor
Idle adjust screw initial setting turns in** 1 1/2 2
L mixture needle initial setting turns back 1 1/4 1 1/2
H mixture needle initial setting turns back 3 2 1/4
Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 1.65 (0.065) lower than diaphragm seat
Chain oil discharge volume at 7000 r/ min Adjustable: 1.5 - 13 (0.05 - 0.40)
mL/min(U.S.fl.oz./min) (Factory set 7 mL/min)
BTDC: Before top dead centre.
*With guide bar and saw chain.
**Set idle adjust screw to contact throttle plate before initial setting.

SERVICE INFORMATION CS-4400
CS-5100
4
1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter Starter pawl M5* 70 - 110 7 - 11 60 - 95
system Starter case M4** 30 - 45 3.0 - 4.5 26 - 40
Ignition Magneto rotor (Flywheel) M8 200 - 240 20 - 24 175 - 210
system Ignition coil M4 35 - 50 3.5 - 5.0 30 - 45
Spark plug M14 150 - 170 15 - 17 130 - 150
Fuel Carburettor M5 30 - 35 3.0 - 3.5 26 - 30
system Intake bellows M5 30 - 45 3.0 - 4.5 26 - 40
(Only CS-5100)
Clutch Clutch hub LM10 300 - 400 30 - 40 260 - 350
Engine Crankcase M5*†70 - 110 7 - 11 60 - 95
Engine mount M5* 70 - 110 7 - 11 60 - 95
Muffler M5 70 - 110 7 - 11 60 - 95
Muffler plate M4 15 - 25 1.5 - 2.5 13 - 22
Others Cylinder cover M4 25 - 45 2.5 - 4.5 22 - 40
Cushion (Front handle) M5 30 - 45 3.0 - 4.5 26 - 40
Oil tank M4 30 - 40 3 - 4 26 - 35
Auto-oiler M4 15 - 25 1.5 - 2.5 13 - 22
Throttle latch M4 6 - 10 0.6 - 1.0 5 - 9
Front handle M5** 45 - 65 4.5 - 6.5 40 - 55
Brake lever (Hand guard) M4 25 - 45 2.5 - 4.5 22 - 40
Chain catcher M5 30 - 45 3.0 - 4.5 26 - 40
Guide bar M8 200 - 230 20 - 23 175 - 200
Sprocket guard plate M4** 10 - 20 1 - 2 9 - 17
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) ** Tapping screw
†The torque differences among four bolts should not exceed 20 kgf•cm (2Nm, 17in•lbf) on one cylinder or
crankcase.

SERVICE INFORMATION
CS-4400
CS-5100 5
1-4 Special repairing materials
Material Location Remarks
Adhesive Ball bearing outer / crankcase Loctite #675 or equivalent
Stud bolt Loctite #609, ThreeBond #1373 or equivalent
Engine cover, cushion Loctite #406 (424) or equivalent
Liquid gasket Crankcase seams Loctite #515 (990610-00051) or equivalent
Oil tank seams Loctite superflex #595, ThreeBond #1212 or
equivalent
Thread locking sealant Starter pawl screws Loctite #242, ThreeBond #1324 or equivalent
Cushion screws (Rear handle)
Engine mount bolts Loctite #222, ThreeBond #1342 or equivalent
Brake weight nut
Crankcase
Grease Auto-oiler worm
Clutch needle bearing
Cushion, inside Lithium based grease
Rewind spring
Oil seal lip
Cleaner lid
Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)

SERVICE INFORMATION CS-4400
CS-5100
6
5K177 5K083 5K084 5K081
5K082 5K016 5K025
5K174
5K178
5K173
123
4567
5K171 5K191B
1-5 Service Limits (CS-4400)
mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 42.87 (1.688)
C Piston pin bore Max. 9.025 (0.3553)
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. 8.980 (0.3535)
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. 12.125 (0.4774)
L Crankshaft runout Max. 0.05 (0.002)
M Sprocket bore Max. 13.07 (0.5146)
N Clutch drum bore Max. 71.5 (2.81)
P Sprocket wear limit Max. 0.5 (0.02)
ABCD
FGH
KLMP
N
E

SERVICE INFORMATION
CS-4400
CS-5100 7
5K177 5K083 5K084 5K081
5K082 5K016 5K025
5K174 5K181 5K097
5K178
5K173
0
5
10
12345678910 11
5K097
1-5 Service Limits (CS-5100)
mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 44.89 (1.767)
C Piston pin bore Max. 11.025 (0.4341)
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. 10.980 (0.4323)
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. 15.025 (0.5915)
L Crankshaft runout Max. 0.05 (0.002)
M Sprocket bore Max. 15.07 (0.5933)
N Clutch drum bore Max. 71.5 (2.81)
P Sprocket wear limit Max. 0.5 (0.02)
ABCD
FGH
KLMP
N
E

SERVICE INFORMATION CS-4400
CS-5100
8
1.35
0.4
1.65
1.5
a
20
20
40
40
60
60
80
80
120
120
140
140
160
160
180
180
20
20
100
100
1-6 Special tools
145 26
910
11 1312 14
15 16 18
3
8
Key Part Number Description Used for:
1 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburettor
2 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolt (M4)
3 895610-79920 L-hex wrench (4 mm) Removing and installing hex. socket bolt (M5)
4 897501-03938 Puller Removing magneto rotor
5 897505-16133 Clutch tool Removing and assembling clutch assembly
6 897537-30130 Piston stopper Locking crankshaft rotation
7 897563-19830 Metering lever gauge Measuring metering lever hight on carburettor
8 897701-02830 Bearing wedge Removing and crankshaft ball bearings
9 897702-30131 Piston pin tool Removing and installing piston pin
10 897603-23030 PTO shaft puller Removing PTO shaft
11 897708-19835 Worm puller Removing auto-oiler worm
12 Y089-000010 Worm inserter Installing auto-oiler worm
13 897724-01361 Spring pin tool Removing and installing spring pin (4 mm or 5/32 in dia.)
14 897726-16431 Oil seal tool Installing oil seals
15 897800-79931 Spark tester Checking ignition system
16 897803-30132 Pressure tester Testing carburettor and crankcase leakage
17 897826-16131 Pressure rubber plug Plugging intake port to test crankcase / cylinder leakages
18 897827-16131 Pressure plate Plugging intake port to test crankcase / cylinder leakages
19 91007 Compression gauge Measuring cylinder compression
a = 3 mm
a = 4 mm
7
17 19

SERVICE INFORMATION
CS-4400
CS-5100 9
2 EMISSION ADJUSTMENT GUIDE
CS-4400
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 45 cm guide bar and saw chain when adjusting carburettor, or
serious engine damage may occur due to overspeeding.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
1. Turn the L and H mixture needles out
anticlockwise to rich side 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 by
hand.
5. Turn Land H mixture needle clockwise until lightly
seated, and then turn out both needles following
turns.
L mixture needles : 1 1/4
H mixture needles : 3
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 1 1/2 turns clockwise.
H
L
(A)
(B)
(B)
(A)
idle adjust screw

SERVICE INFORMATION CS-4400
CS-5100
10
CS-4400
2-3 Adjusting carburettor
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 3,500 r/min by turning idle adjust
screw (in the range of 3,300 to 3,700 r/min allowable).
4. Turn L mixture needle anticlockwise to reduce
engine idle speed 1000 r/min to set idle speed in
the range of 2,300 to 2,700 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
to13,000 r/minby turning H mixtureneedle 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 13,000r/min,
adjust H mixture needle anticlockwise and set
maximum engine speed at less than 13,000 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 2,800 r/min
and at WOT engine speed in the range of 11,500 to
13,000 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.
idle adjust screw
H
L
(A)
(B)
(B)
(A)

SERVICE INFORMATION
CS-4400
CS-5100 11
CB
CS-5100
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 45 cm guide bar and saw chain when adjusting carburettor, or
serious engine damage may occur due to overspeeding.
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle
1. Tools
A. Plug extractor body B. 2.5mm Hexagonal socket
bolt
C. Nut D. 1.5mm blade screw driver
E. L wrench (2mm) F. 2.5mm hand tap
G. Magneto spanner (6mm)
2. Remove carburettor from unit.
3. Make M2.5 x 0.5mm pitch thread using M2.5
hand tap.
4. Fit the nut (C) on hex. socket bolt (B) near the
bolt head. Place extractor body over the limiter
cap. Pass the bolt (B) with nut (C) through the
hole of the extractor body, and screw the bolt in
the limiter cap 5 turns.
C
B
G
A
F
E
D
Locating pin
Limiter cap O-ring

SERVICE INFORMATION CS-4400
CS-5100
12
CS-5100
2-2 Presetting idle adjust screw, L mixture needle and H mixture needle (continued)
5. While holding bolt with L wrench, turn the nut
clockwise to take out the limiter cap.
6. Repeat step No.3 to No.5 for other limiter cap
removal.
7. Temporally insert new limiter caps on both L and
H mixture needle by aligning groove on limiter cap
(B) to locating pin (A) on extension housing. Make it
sure that limiter cap face is leveled with extension
housing top. Do not press limiter cap deeper at this
moment.
8. Turn L and H mixture needles clockwise until
lightly seated using 1.5mm blade screw driver, and
then turn both needles anticlockwise for following
turns.
L mixture needle : 1 1/2
H mixture needles : 2 1/4
Even at this stage, do not press limiter caps in.
9. Reinstall the carburettor on the unit.
A B
Groove

SERVICE INFORMATION
CS-4400
CS-5100 13
CS-5100
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 1.5 mm wide blade screw driver, adjust L
mixture needle to obtain maximum idle speed.
3. Set idle speed to 3,500 r/min by turning idle adjust
screw (in the range of 3,300 to 3,700 r/min allowable).
4. Turn L mixture needle anticlockwise to reduce
engine idle speed 1000 r/min to set idle speed in
the range of 2,300 to 2,700 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 12,000 r/min.
6.Adjust WOT engine speed in the range of 12,500
to 13,500 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 13,500 r/min,
adjust H mixture needle anticlockwise and set
maximum engine speed at less than 13,500 r/min.
8. After adjusting carburettor, Press the caps on L
and H mixture needles as shown.
9. Start engine again and make it sure engine runs
at idle speed in the range of 2,300 to 2,800 r/min
and at WOT engine speed in the range of 12,500 to
13,500 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.