Echo CS-610 Mounting instructions

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.
ECHO SERVICE MANUAL Ord. 401-31
(Model : CS-600) contains lots of informa-
tion for servicing this model.
SERVICE DATA
CHAIN SAW
ECHO: CS-610
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 ......................... 5
1-5 Service limits............................................... 6
1-6 Special tools ............................................... 7
2
CARBURETTOR ADJUSTMENT PROCEDURE
.. 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................................. 10
Reference No. 01-59D-00
ISSUED: 201201
CS-610
01-59D-00 1
0

1 SERVICE INFORMATION
1-1 Specifications
Dimensions Length mm(in) 448 (17.64)
Width mm(in) 246 (9.69)
Height mm(in) 296 (11.65)
Dry weight* kg(lb) 6.0 (13.2)
Engine Type YAMABIKO, 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 7.2
Carburettor Type Diaphragm horizontal-draught
Model Walbro HDA-268A
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) : Kevlar
Fuel Type Premixed two-stroke fuel
Mixture ratio 50 : 1 (2 %)
Petrol Minimum 89 octane gasoline
Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC/FD
Tank capacity L (U.S.fl.oz.) 0.57 (19.3)
Clutch Type Inboard clutch : Centrifugal, 3-shoe slide with 3-tension spring
Guide bar / Saw chain lubrication type Automatic with volume adjuster
Tank capacity, oil 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.
Carlton Saw chain A2LM
Oregon Saw chain 73LGX
Cutting devices
Guide bar Type 45RS58-3/8E 50RS58-3/8E 60RS58-3/8E
Called length cm 45 50 60
Gauge in 0.058
Saw chain Number of drive links 64 72 84
Pitch in 3/8
Gauge in 0.058
SERVICE INFORMATION CS-610
2

1-2 Technical data
Engine
Idling speed r/min 2,800 - 200
+ 400
Wide open throttle speed* r/min 11,800 - 12,800
Clutch engagement speed r/min 4,000
Engagement Minimum†r/min 3,500
Compression pressure MPa (kgf/cm2) (psi) 1.01(10.3)(146)
Ignition system
Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)
Minimum secondary voltage at 1,500 r/min kV 15
Primary coil resistance kΩ117 - 121
Secondary coil resistance kΩ2.5 - 2.9
Pole shoe air gaps mm(in) 0.30 - 0.40 (0.012 - 0.016)
Ignition timing at 3,000 r/min °BTDC 6
at 8,000 r/min °BTDC 24
at 10,000 r/min °BTDC 30
at 12,000 r/min °BTDC 27
PET-9000 Parameter 1 332
Parameter 2 05
Carburettor
Idle adjust screw initial setting turn in** 1
L mixture needle initial setting turns out*** 1 3/4
H mixture needle initial setting turns 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)
mL/min(U.S.fl.oz./min) (Factory set 7.0 mL/min)
BTDC: Before top dead centre.
*With 50 cm guide bar and properly adjusted saw chain.
**Set idle adjust screw to the point that its tip just contacts throttle plate before initial setting.
***Turn L/H mixture needles anticlockwise from point that needle is lightly seated.
†If clutch engagement speed is lower than minimum clutch engagement speed, replace clutch assembly with
new one.
SERVICE INFORMATIONCS-610 3

1-3 Torque limits
Descriptions Size kgf•cm N•m in•lbf
Starter Starter pawl M 5*†60 - 90 6 - 9 50 - 80
system Starter centre shaft screw M 5* 30 - 45 3 - 4.5 25 - 40
Starter case M 5 50 - 70 5 - 7 45 - 60
Ignition Magneto rotor (Flywheel) M 8 230 - 270 23 - 27 200 - 235
system Ignition coil M 4 60 - 90 6 - 9 50 - 80
Spark plug M 14 130 - 170 13 - 17 113 - 150
Fuel Carburettor M 5 30 - 45 3 - 4.5 25 - 40
system Intake bellows M 5 60 - 90 6 - 9 50 - 80
Clutch Clutch hub LM 10 300 - 400 30 - 40 250 - 350
Engine Crankcase M 5†60 - 90 6 - 9 50 - 80
Cylinder M 5†70 - 110 7 - 11 60 - 95
Cylinder cover M 5 60 - 90 6 - 9 50 - 80
Muffler M 5* 70 - 110 7 - 11 60 - 95
Muffler lid M 4 15 - 25 1.5 - 2.5 13 - 22
Others Auto-oiler M 4 35 - 50 3 - 5 25 - 45
Compression Cushion bracket M 5 30 - 40 3 - 4 25 - 35
spring Crankcase M 5 60 - 80 6 - 8 50 - 70
Front handle M 5 40 - 60 4 - 6 35 - 50
M 6 40 - 50 4 - 5 35 - 45
Rear handle M 5 40 - 60 4 - 6 35 - 50
Brake lever Starter side M 5 30 - 50 3 - 5 25 - 40
(Hand guard) Sprocket side M 5 60 - 90 6 - 9 50 - 80
Brake cover M 5* 40 - 60 4 - 6 35 - 50
Sprocket guard plate M 4* 15 - 25 1.5 - 2.5 13 - 22
Spike M 4 60 - 90 6 - 9 50 - 80
Ignition switch M 10 15 - 30 1.5 - 3 13 - 25
Guide bar M 8 200 - 230 20 - 23 175 - 200
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
M 8 110 - 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-610
4

1-4 Special repairing materials
Material Location Remarks
Adhesive Guide bar stud Loctite #609, ThreeBond 1373 or equivalent
Starter centre shaft screw Loctite #222, ThreeBond1342 or equivalent
Grease Auto-oiler worm
Clutch needle bearing
Rubber cushion, inside
Choke knob
Lithium based grease or ECHO XTended
Rewind spring
Protection
TM Lubricant
Oil seal inner lips
Starter centre shaft
Brake cover
Chain brake (metal contact part) Molybdenum grease (approx. 1 gram)
Thread locking sealant Muffler
Sprocket guard plate Loctite #242, ThreeBond #1324 or equivalent
Starter pawl
SERVICE INFORMATIONCS-610 5

5K083 5K084 5K081
5K082 5K016 5K025
5K174 5K181 5K097
5K173
0
5
10
12345678910 11
5K097
5K253
5K254
5K181
ABCD
EFGH
KLMP
N
1-5 Service Limits
Description mm (in)
ACylinder bore When plating is worn and aluminum 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)
SERVICE INFORMATION CS-610
6

b
0
0.4
50
0.8
1.2
1.
MPa
0
Ignition Air Gap Gauge
#.014 = .35mm
P/N 91004
91019
b
b
PET-304
OPPAMA
PET-9000
INTEGRATED IGNITION ANALYZER
1476
2
8
3
9101112
13
20 21 22
14 15 16 18 19
17
5
b = 4 mm
b = 5 mm
b = 6 mm
b = 5.5 mm
1-6 Special tools
Key Part Number Description Used for:
1 G310-000050 Tachometer PET-304 Measuring engine speed to adjust carburettor
2 X605-000050 Torx L wrench (T27) Removing and installing bolt
3 897537-30130 Piston stopper Locking crankshaft rotation
4 897724-01361 Spring pin tool (4 mm) Removing and installing spring pin (4 mm dia)
5 897724-02831 Spring pin tool (5 mm) Removing and installing spring pin (5 mm dia)
6 897719-02830 Piston holder Making piston steady to remove and install piston / rings
7 897702-30131 Piston pin tool Removing and installing piston pin
8 897501-03938 Puller Removing magneto rotor
9 91004 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 91024 Pressure tester Testing crankcase 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 X602-000340 Torx T wrench (T27) Removing and installing bolt
22 900300 Ignition Analyzer : PET-9000
Measuring Ignition timing, Primary/Secondary voltage engine speed
SERVICE INFORMATIONCS-610 7

B
A
B
A
2 CARBURETTOR ADJUSTMENT PROCEDURE
2-1 General adjusting rules
A. 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” 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 50 cm bar and chain should be installed on
the unit. Otherwise serious engine damage will occur due to overspeeding.
B. Adjustment with limiter caps on carburettor.
Set L and H mixture needles fully anticlockwise. Start and run engine for two minutes alternating engine
speed between WOT for 5 seconds and idle for 5 seconds. Adjust idle speed screw to 2,800 +/- 150
r/min. Adjust H mixture needle with limiter cap to 12,500 +/- 300 r/min. If engine does not run correctly af-
ter this adjustment, proceed to the next step 2-2.
IMPORTANT : After adjusting carburettor according to the steps 2-2 and 2-3, the limiter cap(s)
must be installed on L and H mixture needle(s) to comply with Emission Directive.
2-2 Presetting Idle adjust screw, L mixture needle and H mixture needle
Tools Required : Small screwdriver with 2.5 mm
and 4 mm blade, electronic tachometer P/N G310-
000050, limiter cap removal tool with 2.5 mm left-
hand thread P/N 91019. Parts Required : (2) limiter
caps P/N P003-000010.
1. Turn the L and H mixture needles anticlockwise
to rich side stop to align limiter cap tab (A) with lo-
cating slot (B), using 2.5 mm blade screwdriver.
NOTE : If cap tabs (A) misalign with locating slots
(B), the cap cannot be removed and the centre
hole threads will strip. If centre hole threads strip,
use 3 mm diameter thread wood screw to remove
the limiter cap.
(continued)
SERVICE INFORMATION CS-610
8

2-2 Presetting Idle adjust screw, L mixture needle and H mixture needle (continued)
2. Screw 2.5 mm limiter cap removal tool P/N
91019 anticlockwise into centre hole of either lim-
iter cap until tab of the limiter cap just comes out of
the locating slot.
NOTE : DO NOT COMPLETELY REMOVE LIM-
ITER CAP FROM Carburettor!
If the first limiter cap is removed completely, the
second limiter cap can be misaligned while insert-
ing the cap removal tool.
3. Remove the limiter cap removal tool from the
limiter cap by turning the tool clockwise, leaving
the limiter cap in place.
4. Screw 2.5 mm limiter cap removal tool P/N
91019 anticlockwise into centre hole of remaining
limiter cap until the limiter cap is removed from the
mixture needle completely. Remove the limiter cap
from limiter cap removal tool by turning clockwise,
then screw limiter cap removal tool into centre hole
of previous limiter cap to remove completely.
5. Turn L and H mixture needle clockwise until
lightly seated, then turn both mixture needles anti-
clockwise for initial setting as follows :
L mixture needle (C) : 1 3/4,
H mixture needle (D) : 3/4
NOTE : If needles are forced during seating, dam-
age to carburettor may occur.
6. Remove air cleaner lid and air filter to expose
the Idle adjust screw (E) and throttle plate. Turn
Idle adjust screw anticlockwise and set the screw
until the tip just contacts the throttle plate. Then
turn Idle adjust screw 1 turn clockwise. Reinstall
air filter, and cleaner lid.
NOTE : The initial carburettor settings for Idle
adjust screw, L and H speed 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.
(C)
(E)
(D)
SERVICE INFORMATIONCS-610 9

A
B
A
B
(E)
(D) (C)
(F)
(f)
2-3 Adjusting carburettor
1. Start and warm engine for 1 minute alternating
engine speed between WOT and idle every 5 sec-
onds. Turn H mixture needle (D)
anticlockwise until
engine speed drops to approx. 11,500 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 (C) using 2.5mm blade
screwdriver to reach maximum engine speed just
before lean speed drop off.
3. Set idle speed to 3,600 r/min by turning Idle
adjust screw (E). Engine speed should be stable
at 3,600 +/- 50 r/min after Idle adjust screw
adjustment.
4. Turn L mixture needle (C) anticlockwise reducing engine idle speed 800 r/min to set idle speed at 2,800
r/min. The idle speed range is 2,750 - 2,850 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. Before adjustment, WOT engine speed should be 11,500 r/min or less. If engine speed is higher, turn
H mixture needle
anticlockwise until 11,500 r/min is achieved. To make the final WOT engine speed ad-
justment, turn the H mixture needle
clockwise in 1/8 turn increments with the engine at idle. After each
adjustment, accelerate to WOT, and check speed. The final speed should fall within 12,100 - 12,300 r/min
at WOT.
NOTE : When the H mixture needle is turned completely clockwise, the engine will continue to run. If the
engine speed at WOT is above 13,300 r/min, adjust H mixture needle anticlockwise and set maximum
engine speed at less than 13,000 r/min.
6. After adjusting carburettor, put new limiter
cap on the other side (f) of limiter cap tool (F) as
shown. Align the limiter cap’s tabs (A) with locating
slots (B) in extended housing of carburettor and
press the limiter caps to the bottoms on L and H
mixture needles respectively.
IMPORTANT : The limiter caps must be properly installed on L and H mixture needles to comply
with Emission Directive.
7. Start engine, and verify engine idle speed ranges from 2,600 to 3,200 r/min, and WOT engine speed
ranges from 11,800 to 12,800 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.
SERVICE INFORMATION CS-610
10