Echo CS-500ES Mounting instructions

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)
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 ......................... 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
2
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
4
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
N
E
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
6




Ignition Air Gap Gauge
#.014 = .35mm
P/N 91004






03D

233$0$
3(7
,17(*5$7(',*1,7,21$1$/<=(5
E
'
PET-304





1-6 Special tools
134
5
2
69
10 11 1312
14
8
7
16
15
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.
1
7
4
3
2
(A)
(B) (C)
(D)

SERVICE INFORMATION CS-500ES
8
2-3 Adjusting carburettor
1.
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)
(A)