Echo CS-600 User manual

Ref. No. 401-31
REVISED NOV. 2015
(Serial number: 36000001 and after)
CS-600

INTRODUCTION
This service manual contains information for ser-
vice and maintenance of ECHO CHAIN SAW,
model CS-600.
For systematic diagnosis, to avoid extra work,
time loss and to meet Emission regulation,
please refer to “Troubleshooting guide” that
describes problems, testing, remedies and
references. We recommend you make use of
Operator’s Manual and Parts Catalogue together
with this manual when servicing.
We are constantly working on technical improve-
ment of our products. For this reason, technical
data, equipment and design are subject to
change without notice. All specifications, illustra-
tions and directions in this manual are based on
the latest product information available at the
time of publication.

TABLE OF CONTENTS
CS-600 1
Page Page
1 SERVICE INFORMATION.....................................2
1-1 Specifications ...................................................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 STARTER SYSTEM..............................................8
2-1 Disassembling starter assembly.......................9
2-2 Replacing starter rope....................................10
2-3 Assembling starter.......................................... 11
2-4 Replacing starter pawl....................................13
3 IGNITION SYSTEM.............................................14
3-1 Troubleshooting guide....................................15
3-2 Testing spark ..................................................16
3-3 Inspecting spark plug .....................................16
3-4 Inspecting ignition switch................................17
3-5 Replacing ignition switch................................18
3-6 Inspecting ignition coil resistance...................19
3-7 Replacing spark plug cap and coil..................20
3-8 Replacing ignition coil.....................................20
3-9 Setting pole shoe air gaps..............................21
3-10 Inspecting flywheel and key ...........................21
4 FUEL SYSTEM ...................................................23
4-1 Inspecting air filter ..........................................24
4-2 Inspecting fuel cap and fuel strainer...............24
4-3 Inspecting fuel tank and line...........................25
4-4 Inspecting and replacing tank vent.................26
4-5 Replacing fuel line..........................................28
4-6 Adjusting carburettor ......................................29
4-6-1 General adjustment rules ...............................29
4-6-2 Initial setting Throttle adjust screw, L mixture
needle and H mixture needle .........................29
4-6-3 Adjusting carburettor ......................................31
4-7 Air shutter.......................................................32
4-8 Testing carburettor..........................................33
4-9 Inspecting crankcase pulse passage .............34
4-10 Inspecting metering lever height ....................34
4-11 Inspecting inlet needle valve ..........................35
4-12 Inspecting diaphragm.....................................36
4-13 Replacing Welch plug.....................................37
4-14 Installing carburettor.......................................38
5 CLUTCH SYSTEM..............................................39
5-1 Inspectng clutch parts ....................................40
5-2 Replacing clutch parts....................................41
5-3 Installing clutch assembly...............................41
6 CHAIN BRAKE SYSTEM....................................43
6-1 Disassembling chain brake ............................44
6-2 Assembling brake parts..................................45
7 SAW CHAIN LUBRICATION SYSTEM...............46
7-1 Inspecting oil cap and strainer........................47
7-2 Inspecting auto-oiler assembly and oil line.....48
7-3 Inspecting oil tank vent...................................49
7-4 Replacing oil line and grommet......................50
7-5 Disassembling auto-oiler assembly................51
7-6 Inspecting V-ring.............................................52
7-7 Assembling auto-oiler parts............................53
8 ENGINE...............................................................54
8-1 Testing cylinder compression .........................55
8-2 Cleaning cooling air passages .......................55
8-3 Inspecting muffler and exhaust port ...............56
8-4 Testing crankcase and cylinder seal...............57
8-5 Inspecting cylinder..........................................58
8-6 Inspecting piston and piston ring....................59
8-7 Replacing oil seal ...........................................60
8-8 Disassembling crankcase...............................60
8-9 Replacing ball bearing and oil seal.................61
8-10 Assembling crankshaft and crankcase...........62
8-11 Installing piston...............................................63
8-12 Installing piston ring and cylinder ...................64
9 REAR HANDLE AND CONTROL SYSTEM.......65
9-1 Replacing cushions ........................................66
9-2 Replacing throttle trigger ................................67
10 GUIDE BAR MOUNTING SYSTEM..................69
10-1 Replacing chain tensioner..............................70
10-2 Replacing guide bar stud................................70
10-3 Installing guide bar stud .................................71
11 MAINTENANCE GUIDE....................................72
11-1 Troubleshooting guide....................................72
11-2 Disassembly Chart .........................................74
11-3 Service Intervals.............................................75
INDEX......................................................................76

SERVICE INFORMATION CS-600
2
1 SERVICE INFORMATION
1-1 Specifications
Dimensions Length mm(in) 448 (17.64)
Width mm(in) 245 (9.65)
Height mm(in) 292 (11.50)
Dry weight* kg(lb) 5.9 (13.0)
Engine Type KIORITZ, air-cooled, two-stroke, single cylinder
Ventilated piston, Semi-automatic decompression
Rotation Clockwise as viewed from the output end
Displacement cm3(in3) 59.8 (3.649)
Bore mm(in) 45.0 (1.772)
Stroke mm(in) 37.6 (1.480)
Compression ratio 6.8
Carburettor Type Diaphragm horizontal-draught
Model Walbro HDA-268
Venturi size-Throttle bore mm(in) 15.08 - 19.03 (0.594 - 0.749)
Ignition Type CDI (Capacitor discharge ignition) system
Digital magneto
Spark plug BPMR8Y
Exhaust Muffler type Spark arrester muffler
Starter Type Automatic rewind
Rope diameter x length mm(in) 4.0 x 950 (0.15 x 37.4)
Fuel Type Premixed two-stroke fuel
Mixture ratio 50 : 1 (2 %)
Petrol Minimum 89 octane petrol
Two-stroke air cooled engine oilISO-L-EGD (ISO/CD13738), JASO FC/FD
Tank capacity L (U.S.fl.oz.) 0.57 (19.3)
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.) 0.3 (10.1)
Sprocket Type Floating rim
Number of teeth 7
Pitch in 3/8
* Without guide bar and saw chain.
Cutting devices
Guide bar Type 45RS58-3/8E 50RS58-3/8E 60RS58-3/8E
(S45R73-64AA) (S50R73-72AA) (S60R73-84AA)
Called length cm 45 50 60
Gauge in 0.058
Saw chain Type CARLTON A2LM Oregon 73LGX
Number of drive links 64 72 84
Pitch in 3/8
Gauge in 0.058

SERVICE INFORMATION
CS-600 3
1-2 Technical data
Engine
Idling speed r/min 2,600 - 3,200
Wide open throttle speed* r/min 12,000 - 13,000
Clutch engagement speed r/min 3,800 - 4,300
Compression pressure MPa (kgf/cm2) (psi) 0.94 (9.6) (136)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1,200 r/min kV 13
Secondary coil resistance kΩ1.7 - 2.2
Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)
Ignition timing at 3,000 r/min °BTDC 11
at 8,000 r/min °BTDC 32
at 12.000 r/min °BTDC 31
Carburettor
Throttle adjust screw initial setting turn in** 2 3/8
L mixture needle initial setting turn out*** 2
H mixture needle initial setting turn out*** 3/4
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 7,000 r/min Adjustable: 1.5 - 13 (0.05 - 0.39)
(Factory set: 7.0 mL/min)
mL/min(U.S.fl.oz./min)
BTDC: Before top dead centre.
* With 50 cm guide bar and properly adjusted saw chain.
**Set throttle adjust screw to the point that its tip contacts throttle plate before initial setting.
***Turn L/H mixture needles anticlockwise from point that needle is lightly seated.

SERVICE INFORMATION CS-600
4
1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter system Starter pawl M5*†60 -90 6 -950
-80
Starter centre shaft screw M5* 30 -45 3 -4.5 25 -40
Starter case M5 50 -70 5 -745
-60
Ignition system Magneto rotor (Flywheel) M8 230 -270 23 -27 200 -235
Ignition coil M4 60 -90 6 -950
-80
Spark plug M14 130 -170 13 -17 113 -150
Fuel system Carburettor M5 30 -45 3 -4.5 25 -40
Intake bellows M5 60 -90 6 -950
-80
Clutch Clutch hub LM10 300 -400 30 -40 250 -350
Engine Crankcase M5†60 -90 6 -950
-80
Cylinder M5†70 -110 7 -11 60 -95
Cylinder cover M5 60 -90 6 -950
-80
Muffler M5* 70 -110 7 -11 60 -95
Muffler lid M4 15 -25 1.5 -2.5 13 -22
Others Auto-oiler M4 35 -50 3 -525
-45
Compression
Cushion bracket
M5 30 -40 3 -425
-35
spring Crank case M5 60 -80 6 -850
-70
Front handle M5 40 -60 4 -635
-50
M6 40 -50 4 -535
-45
Rear handle M5 40 -60 4 -635
-50
Brake lever Starter side M5 30 -50 3 -525
-40
(Hand guard) Sprocket side M5 60 -90 6 -950
-80
Brake cover M5* 40 -60 4 -635
-50
Sprocket guard plate M4* 15 -25 1.5 -2.5 13 -22
Spike M4 60 -90 6 -950
-80
Ignition switch M10 15 -30 1.5 -313
-25
Guide bar M8 200 -230 20 -23 175 -200
Regular bolt, nut and screw M3 6 -10 0.6 -15
-9
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
LM: Left-hand thread
*Thread locking sealant (See next page)
†The torque difference between four bolts should not exceed 20 kgf•cm (2N•m, 17in•lbf) per bolt.

SERVICE INFORMATION
CS-600 5
1-4 Special repairing materials
Material Location Remarks
Adhesive Guide bar stud Loctite #609, ThreeBond 1373 or equivalent
Starter centre shaft screw Loctite #222, ThreeBond 1342 or equivalent
Grease Auto-oiler worm
Lithium based grease
or ECHO XTended
Protection TM
Lubricant
Clutch needle bearing
Rubber cushion, inside
Choke knob
Rewind spring
Oil seal inner lips
Starter centre shaft
Brake cover
Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)
Thread locking sealant Muffler
Loctite #242, ThreeBond #1324 or equivalentSprocket guard plate
Starter pawl

SERVICE INFORMATION CS-600
6
Description mm (in)
ACylinder bore When plating is worn and aluminium can be seen
BPiston outer diameter Min. 44. 90 (1.768)
CPiston pin bore Max. 11. 030 (0.4343)
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. 5 (0.02)
KCon-rod small end bore Max. 15. 025 (0.5915)
LCrankshaft runout Max. 0. 01 (0.001)
MSprocket bore Max. 13. 90 (0.5472)
NClutch drum bore Max. 71. 5 (2.81)
PSprocket wear limit Max. 0. 5 (0.02)
5K083 5K084 5K081
5K082 5K016 5K025
5K174 5K181 5K097
5K173
0
5
10
1234567891011
5K097
5K253
5K254
5K181
ABCD
EFGH
KLMP
N
1-5 Service Limits

SERVICE INFORMATION
CS-600 7
Key Part Number Description Reference
1G310-000050 Tachometer PET-304 Measuring engine speed to adjust carburettor
2X602-000340 Torx wrench (T27) Removing and installing bolt
3897537-30130 Piston stopper Locking crankshaft rotation
4897724-01361 Spring pin tool (4 mm) Removing and installing spring pin (4 mm dia)
5897724-02831 Spring pin tool (5 mm) Removing and installing spring pin (5 mm dia)
6897719-02830 Piston holder Making piston steady to remove and install piston / rings
7897702-30131 Piston pin tool Removing and installing piston pin
8897501-03938 Puller Removing magneto rotor
991004 Module air gap gauge Adjusting pole shoe air gaps
10 897502-19830 Crankcase tool Separating crankcase
11 897701-14732 Bearing tool Removing and installing ball bearings on crankcase
12 91037 Compression gauge Measuring cylinder compression
13 91019 Limiter cap tool Removing and installing limiter cap
14 91139 Pressure / vacuum tester Testing crankcase / cylinder leakages
15 897726-16431 Oil seal tool Installing starter side oil seal
16 897826-16131 Pressure rubber plug Plugging intake port to test crankcase / cylinder leakages
17 897827-16131 Pressure plate Plugging intake port to test crankcase / cylinder leakages
18 897800-79931 Spark tester Checking ignition system
19 897803-30133 Pressure tester Testing carburettor leakages
20 897714-12330 Oil seal tool Installing crankcase side oil seal
21 91041 Pressure rubber plug Plugging exhaust port to test crankcase / cylinder leakages
22 101115-37531 Plug Testing crankcase / cylinder leakages
23 900720-00009 O-ring Testing crankcase / cylinder leakages
24 897505-16133 Clutch tool Removing and installing clutch assembly
b = 4 mm
b = 5 mm
1-6 Special tools
13
20
2
19
8910
12
11
13
7
6
16
18
14 15
4
5
21 24 22
23
b
Ignition Air Gap Gauge
#.014 = .35mm
P/N 91004
91019
Made in Germany
T27x200
4 0 1 0 5 5 7 86 9 7 4 5
PET-304
17

STARTER SYSTEM CS-600
8
2 STARTER SYSTEM
(A) Starter case (G) Starter rope
(B) Rope guide (H) Fan cover
(C) Starter grip (J) Starter pawl
(D) Rewind spring (K) Flywheel
(E) Rewind spring case
(F) Rope reel
(E)
(D)
(A)
(C)
(B)
(H)
(F)
(G)
(K)
(J)

STARTER SYSTEM
CS-600 9
2-1 Disassembling starter assembly
1. Remove sprocket guard (A).
2. Remove brake lever (B).
3. Remove four screws and remove starter assem-
bly (C) from unit.
4. Pull out starter rope about 30 cm (12 in) and
hold rope reel (D) by hand. Loop excess rope in
rope reel notch (d) as shown.
5. Rotate rope reel (D) counterclockwise to release
tension of rewind spring.
6. Remove bolt (E).
7. Remove washer (F) and starter drum (G).
8. Carefully remove rewind spring and case (H)
as one piece. Rewind spring is under tension and
may release unexpectedly.
WARNING DANGER
Wear eye protection and take care when
removing starter drum. Rewind spring may
unwind suddenly and cause personal injury.
A
D
d
B
C
E
F
G
H

STARTER SYSTEM CS-600
10
2-2 Replacing starter rope
1. Pull out and untie knot (A).
2. Pull knot (B) to remove rope from rope reel (C).
4. Make a knot (D) at end of starter rope and pass
the rope through hole of rope reel, then press the
knot (D) into recess as shown.
4K287
D
3. When installing a new starter rope, singe both
ends of the rope to prevent fraying.
5. Pass the other end of starter rope through
rope guide on starter case, then pass starter rope
through starter grip and make a knot as shown.
6. Tighten knot. Push knot into recess of starter
grip.
A
B
C
D
D

STARTER SYSTEM
CS-600 11
2. Carefully install rewind spring and case (B) on
starter case (C) as one piece. Match large ear
(b1) and small ear (b2) with posts (c1) and (c2) on
starter case.
3. Assemble rope reel (D) engaging hook (d) with
hook (a) of rewind spring.
4. Check for proper engagement of rewind spring
and rope reel by turning rope reel (D) clockwise
and counterclockwise.
2-3 Assembling starter
1. If rewind spring (A) is removed from spring case
(B), rewind inside case as shown.
B
A
d
Da
C
B
b2
b1
D
c1 c2

STARTER SYSTEM CS-600
12
7. Pull starter several times to check rewind spring
tension. If starter is not rewinding fully, increase
spring tension by rotating rope reel one more turn
clockwise following above step (6).
8. Pull out starter rope all the way, and check that
rope reel can be rotated an additional half or more
turn clockwise as shown, to prevent rewind spring
from breaking.
9. If rope reel can not be turned clockwise, reduce
tension by rotating rope reel counterclockwise one
turn with starter rope hooked at notch (G).
5. Reinstall washer (E) and bolt (F) on starter post.
6. Pull out starter rope inside starter case. Rotate
rope reel clockwise several turns with starter rope
hooked at notch (G) as shown. Hold rope reel to
prevent it from unwinding and pull out starter grip
to take the rope slack.
2-3 Assembling starter (continued)
G
E
F

STARTER SYSTEM
CS-600 13
1. Remove starter assembly from unit.
2. Loosen bolt (A) and remove washer, pawl (B),
spacer (C) and torsion spring (D). Replace dam-
aged or worn parts.
NOTE: When it is hard to loosen bolt, install Piston
stopper 897537-30130 (E) in spark plug hole to
stop crankshaft rotation and remove bolt easily.
3. Install torsion spring, spacer, pawl, washer and
bolt. To avoid pinching of torsion spring, install
these parts without setting the end (F) of torsion
spring on starter pawl. The bolt is pre-coated with
sealant on the thread. If the sealant is peeled off,
apply thread locking sealant (Loctite #242, Three-
Bond #1324 or equivalent).
4. Using fine wire (G) or appropriate tool, place the
end (F) of torsion spring on pawl (B), by hooking
and passing under pawl as shown. Remove fine
wire or tool.
5. Make sure pawl can move smoothly. If it does
not move smoothly, check parts for correct installa-
tion.
2-4 Replacing starter pawl
F
G
B
D
C
B
A
E
F

IGNITION SYSTEM CS-600
14
3 IGNITION SYSTEM
(A)
(B)
(C)
(D)
(E)
(G)
(H)
(F)
(A) Flywheel (F) Spark plug cap
(B) Ignition coil (G) Switch lead
(C) Spark plug (H) Ground lead
(D) Cap cover (I) Ignition switch
(E) Spark plug cap coil
(I)

IGNITION SYSTEM
CS-600 15
3-1 Troubleshooting guide
Not
OK
Not
OK
Not
OK
OK
OK
OK
Spark plug
Spark
plug cap/
coil
Ignition
switch
Clean /
Regap /
Replace.
Replace.
Start
OK
OK
S.T.
Not
OK
S.T.
Not
OK
Not
OK
S.T.
OK
S.T.
Not
OK Pole
shoe air
gaps
Replace.
Not
OK OK
Not
OK
S.T.
OK
OK
Replace
ignition
coil.
Leads
connections
Not
OK
OK
OK
Not
OK
S.T.
Repair /
Replace.
Not
OK
Remedy
Inspect
Not
OK
Flywheel
key
OK
R.T.*
End
Not
OK
Flywheel
magnet
Replace.
Not
OK
R.T.
Not
OK
OK
OK
Replace ignition coil and / or inspect other
systems.
Replace flywheel.
OK
OK
Adjust pole shoe air gaps.
(Inspect flywheel magnet
at the same time. Go to
Aif OK.)
S.T.
Not
OK
A
S.T.: Spark test.
R.T.: Running test including actual cutting.
OK
OK
Secondary
coil
resist-
ances

IGNITION SYSTEM CS-600
16
3-2 Testing spark
1. Remove cleaner lid and cylinder cover. Remove
spark plug cap from spark plug.
2. Connect Spark tester 897800-79931 (A) to high
tension lead and connect tester lead (B) on spark
plug.
3. Screw in adjuster (a1) until the needle tips con-
tact. Turn out adjuster (a1) 4 turns to set spark
tester gap (a2) to 4 mm (0.16 in).
4. Turn ignition switch to “I” position. Pull starter
grip several times.
5. If spark is steady blue or white at the tester gap,
ignition system is considered good. Go to inspect-
ing spark plug.
6. If no spark exists or spark is intermittent in
yellow, orange, or red, continue with further inspec-
tion.
DANGER
*Do not test near spark plug hole without
spark plug installed, otherwise there is a
chance to ignite fuel mixture inside cylinder.
*Do not touch metal parts of spark tester
while performing the test to avoid receiving
electrical shock.
*Do not check spark in area where gasoline
is spilled or flammable gases may exist.
3-3 Inspecting spark plug
1. Remove spark plug to inspect for fouling,
cracked or broken insulator, cracked outer elec-
trode, or rounded center electrode. Clean or
replace spark plug as required.
2. Set spark plug gap (A) by bending outer elec-
trode (B).
Standard : 0.6 to 0.7 mm (0.024 to 0.028 in)
NOTE: Take care not to crack outer electrode
when bending.
3. If engine does not start with correct spark plug,
inspect if spark plug is wet or dry. If it is exces-
sively wet or dry, inspect fuel system.
A
B
a2
GASO
LINELINE
B
a1
A
a2

IGNITION SYSTEM
CS-600 17
3-4 Inspecting ignition switch
1. Remove cleaner lid and cylinder cover.
2. Remove switch lead (A) from ignition coil.
3. Connect one probe of Ohm-meter or multi-meter
to switch lead. Connect the other probe to cylinder
fin (B).
4. When ignition switch is in “I” position, tester
should indicate infinite resistance.
5. When ignition switch is in “O (STOP)” position,
tester should show that the circuit is in conducting
state (closed circuit).
6. If ignition switch is defective, replace with a new
one.
B
A

IGNITION SYSTEM CS-600
18
3-5 Replacing ignition switch
1. Remove cleaner lid and cylinder cover.
2. Remove two bolts and remove cleaner case (A).
3. Loosen nut (B), and remove ignition switch (C)
and ground lead (D) from the unit. Remove switch
lead (E) from ignition switch.
4. Assemble ground lead (D) and new ignition
switch on the unit, aligning notch of ignition switch
with tab (F) of the unit. Fasten nut (B) on ignition
switch.
5. Assemble switch lead (E) to ignition switch.
C
E
D
B
F
D
B
E
A