Echo CS-8001 Series Mounting instructions

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.
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1
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3
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
2
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
4
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
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0
5
10
123
45678910 11
5K083 5K084 5K081
5K082 5K016 5K042 5K172
5K173 5K175 5K171 5K097
5K171
1-5 Service Limits
ABCD
EFGH
KLMP
N
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
a
b
20
20
40
40
60
60
80
80
120
120
140
140
160
160
180
180
20
20
100
100
1-6 Special tools
15
7
2
811
12 13 15 17 18
19 21
3
9
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
20
6
4
10
14
16
b = 3 mm
b = 4 mm
b = 5 mm
23
22

SERVICE INFORMATION CS-8001
8
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
L
H
(C)
(A)
(B)
(B)
(A)
HL

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
HL
(A)
(B)
(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.
HL
(A)
(B)
(B)
(A)