Echo CS-600 Service Manual Download Page 62

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ENGINE

CS-600

8-7 Replacing oil seal

1. Pry defective oil seal from crankcase.

NOTE:

Be careful not to damage crankshaft and

oil seal housing.

NOTE:

Before removing

ywheel side oil seal, re-

move woodruff key.

2. Apply lithium based grease or ECHO XTended
Protection Lubricant on inner rubber lips of new oil
seal.

3. Lubricate circumferences of new oil seal with
high melting point grease.

4. Push in new oil seal (A) until

ush with crank-

case surface (B) using Oil seal tool 897726-16431
(C).

8-8 Disassembling crankcase

1. Referring to “11-1 Disassembly chart”, remove
necessary parts for crankcase disassembly.

2. Remove 6 bolts (A) from crankcase.

3. Install Crankcase tool 897502-19830 (B) with 3
bolts on one side of crankcase halves (in the pic-
ture,

ywheel side is shown).

4. Tighten bolt (C) to pull crankcase halves apart.

5. Crankshaft remains on the other side of crank-
case halves, and can be removed by the same
procedure with Crankcase tool 897502-19830.

6. Clean and inspect crankshaft and crankcase for
damage and discoloration.

Summary of Contents for CS-600

Page 1: ...Ref No 401 31 REVISED NOV 2015 Serial number 36000001 and after CS 600 ...

Page 2: ...es 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 pro...

Page 3: ...cting 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 Inspec...

Page 4: ...k 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 oil ISO 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 Sa...

Page 5: ... 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 o...

Page 6: ... 60 95 Muffler lid M4 15 25 1 5 2 5 13 22 Others Auto oiler M4 35 50 3 5 25 45 CompressionCushion bracket M5 30 40 3 4 25 35 spring Crank case M5 60 80 6 8 50 70 Front handle M5 40 60 4 6 35 50 M6 40 50 4 5 35 45 Rear handle M5 40 60 4 6 35 50 Brake lever Starter side M5 30 50 3 5 25 40 Hand guard Sprocket side M5 60 90 6 9 50 80 Brake cover M5 40 60 4 6 35 50 Sprocket guard plate M4 15 25 1 5 2 5...

Page 7: ...Bond 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 equivalent Sprocket guard plate Starter pawl ...

Page 8: ...0 004 F Piston pin outer diameter Min 10 98 0 4323 G Piston ring width Min 1 45 0 057 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 01 0 001 M Sprocket bore Max 13 90 0 5472 N Clutch drum bore Max 71 5 2 81 P Sprocket wear limit Max 0 5 0 02 5K083 5K084 5K081 5K082 5K016 5K025 5K174 5K181 5K097 5K173 0 5 10 1 2 3 4 5 6 7 8 9 10 11 5K097 5K2...

Page 9: ...sion 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 Spar...

Page 10: ...ARTER 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 ...

Page 11: ...oop 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 ...

Page 12: ... 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 ...

Page 13: ...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 D a C B b2 b1 D c1 c2 ...

Page 14: ... 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 t...

Page 15: ...o 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 f...

Page 16: ...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 ...

Page 17: ...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 A if OK S T Not OK A S T Spark test R T Running test ...

Page 18: ...on 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...

Page 19: ... 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 ...

Page 20: ...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 ...

Page 21: ...sure secondary coil resistance Secondary coil resistance should be in the range of 1 7 to 2 2 kΩ 4 If the meter reading indicates infinite resistance remove spark plug cap and spark plug cap coil and measure resistance between the conduction wire of high tension lead and ignition coil core 5 If the reading at step 2 or 3 is not in the range of 1 7 to 2 2 kΩ replace with a new ignition coil Go to 3...

Page 22: ...air gaps Tighten two bolts B Reinstall fan cover starter assembly and cylinder cover 8 Connect spark plug cap to spark plug Reinstall cleaner lid 3 7 Replacing spark plug cap and coil 1 Disconnect spark plug cap A with cap cover from spark plug Remove cap cover from spark plug cap 2 Apply some oil in spark plug cap A for easy re moval from high tension lead B 3 Pull spark plug cap away from high t...

Page 23: ...ove nut B by rotating counterclockwise 3 9 Setting pole shoe air gaps 1 Insert Module air gap gauge 91004 A or 0 3 0 4 mm 0 012 0 016 in thick feeler gauge be tween flywheel and ignition coil shoes 2 Rotate flywheel until magnetic poles of flywheel face ignition coil shoes 3 Hold ignition coil against flywheel and tighten the bolts to specified torque Refer to Service in formation 1 3 Torque limit...

Page 24: ...ernately to re move flywheel 7 Inspect woodruff key for damage or shearing Replace as required 8 Wipe off oil from taper part of crankshaft before assembling flywheel 9 Install woodruff key into key groove 10 Reinstall starter pawls Refer to 2 4 Replacing starter pawl 11 Align flywheel key groove with woodruff key on crankshaft Install flywheel and fasten flywheel nut clockwise C ...

Page 25: ...600 23 4 FUEL SYSTEM A Fuel cap B O ring C Connector D Fuel tank E Fuel tank vent F Fuel strainer G Pulse line H Fuel line J Grommet K Carburettor L Cleaner case M Air filter N Cleaner lid L M D E G A B F C H K N J J ...

Page 26: ...om flying particles 3 If heavily blocked with dirt or dust clean air filter with compressed air 4 Replace air filter with new one if heavily soiled or damaged 4 2 Inspecting fuel cap and fuel strainer 1 Remove fuel cap 2 Inspect fuel cap for cracks and O ring A for cuts or damage and replace with new one as re quired 3 Replace connector B if damaged 4 Pull fuel strainer C from fuel tank using a wi...

Page 27: ...th longnose pliers as shown NOTE Wrap the ends of longnose pliers with tape or cover with soft pipes to protect fuel line from damage 7 Apply pressure approx 49 kPa 0 5 kgf cm2 7 psi 8 If pressure drops replace fuel line 9 Put fuel strainer in fuel tank and fasten fuel cap securely 10 Apply pressure approx 9 8kPa 0 1 kgf cm2 1 4 psi 11 Pressure should not drop If pressure drops leakage may occur f...

Page 28: ...onnect Pressure vacuum tester 91139 B 2 Apply pressure approx 49 kPa 0 5 kgf cm2 7 psi Make sure pressure is stable in range of 9 8 39 2 kPa 0 1 0 4 kgf cm2 1 4 5 7 psi 3 If it is not in the range gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valves in tank vent as sembly Damage to valves will occur 4 Apply negative pressure 19 6 kPa 0 2 kgf cm2 3 psi 5...

Page 29: ... gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valves in tank vent as sembly Damage to valves will occur 4 Remove cap C of tank vent and clean sponge D 5 Cut pipe 363011 00210 E 7x11x170mm and 382011 01110 F 9x13x350 in approx 30mm 1 1 4 in length and connect them to pressure tester as shown Connect tank vent A without cap to pipe as shown 6 Plug hole a...

Page 30: ...move fuel strainer E and clip F from fuel line G 5 Remove fuel line connector H from grommet J together with fuel lines Replace them if defective 6 Assemble new lines A 135mm and G 120mm on fuel line connector H Pass fuel line G through grommet Push fuel connector into grommet 7 Pull out fuel line from fuel tank and install clip and fuel strainer to fuel line 8 Reinstall carburettor cleaner case a...

Page 31: ...adjust screw to 2 800 150 r min Adjust H mixture needle to 12 500 300 r min If engine does not run correctly after this adjust ment 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 4 6 2 Initial setting Throttle adjust screw L mixture needle and H m...

Page 32: ...g clockwise then screw limiter cap removal tool into centre hole of previous limiter cap to remove completely 5 With 2 5 mm blade screwdriver turn L and H mixture needles clockwise until lightly seated Fig 4 then turn out both mixture needles follow ing turns L mixture needle 2 H mixture needle 3 4 NOTE If needles are forced during seating dam age to carburettor may occur 6 Remove air cleaner lid ...

Page 33: ...500 rpm or less If rpm is higher turn H mixture needle anticlockwise until 11 500 rpm is achieved To make the final WOT engine speed adjustment turn H mixture needle clockwise in 1 8 turn increments with the engine at idle After each adjustment acceler ate to WOT and check rpm The final rpm should fall within 12 100 12 500 rpm at WOT NOTE When H mixture needle is turned completely clockwise the en...

Page 34: ...located in cleaner case A 2 Picture shows normal position of air shutter B rear view 3 Slide air shutter B to open air duct and intro duce warm air from cylinder side to carburettor box rear view NOTE In order to avoid carburettor vapor lock return air shutter to normal position when tempera ture is above freezing B A B B B ...

Page 35: ...Pa 0 5 kgf cm2 7 psi 5 If reading does not drop inspect inlet needle valve for sticking or metering lever height is too low 6 If pressure drops at step 2 or if pressure drops below standard figure at step 4 remove carburet tor from the unit disconnecting pulse line throttle rod and choke knob 7 Submerge carburettor in suitable clean solvent to locate the leak by applying pressure approx 98 kPa 1 k...

Page 36: ...ssary gently bend metering lever up or down to set the metering lever to proper position NOTE When metering lever is Too high Fuel flooding occurs Too low Fuel starvation overheating occurs 4 9 Inspecting crankcase pulse passage 1 Drop a little oil in the end of pulse line A as shown 2 Remove spark plug and pull starter grip several times Oil should spit back from the hole 3 If not inspect whether...

Page 37: ...ows Improper assembling of metering lever and spring Dirt between inlet needle valve and valve seat Worn inlet needle valve tip 3 Clean inlet needle valve seat using suitable clean solvent do not use metal tools 4 Reassemble inlet needle valve spring metering lever and pivot pin NOTE Insure proper metering lever installation as follows 1 Spring is seated in its hole at chamber floor 2 Spring is un...

Page 38: ...pump gasket D and replace if defective 5 Inspect inlet screen F if blocked remove and clean it or replace 6 Clean fuel passages in carburettor body with compressed air NOTE Before cleaning metering side with com pressed air turn H needle clockwise until lightly seated and remove inlet needle valve Otherwise main nozzle check valve and inlet needle valve spring may be damaged by the compressed air ...

Page 39: ... parts to pro tect them from damage 2 To remove Welch plug A punch the remover tool B through Welch plug at low angle and pry it out NOTE Remover tool B and welch plug installer C are included in Welch plug tool kit Part num ber 500 500 3 Clean low speed ports with compressed air 4 Place a new Welch plug over the opening and gently tap it until flush using welch plug installer C 5 Install all remo...

Page 40: ...carburettor 2 Connect fuel line B and pulse line C to carbu rettor as shown 3 Connect choke rod D to carburettor Install choke rod to rear handle with choke grommet E 4 Secure carburettor and cleaner case F with two bolts G Assure intake pipe H engages cor rectly A B C D E G F H ...

Page 41: ...5 CLUTCH SYSTEM A Circular washer B Worm gear C Collar D Clutch plate E Clutch spring F Clutch shoe G Clutch hub H Clutch assembly J Needle bearing K Clutch drum L Sprocket M Circular washer N E Ring J K E D C B A G F L M N H ...

Page 42: ...30130 H in spark plug hole to stop crankshaft rotation 6 Rotate clutch assembly clockwise by hand until it cannot be rotated further 7 Loosen clutch assembly Left hand thread ro tating clockwise with Clutch tool 897505 16133 J and remove it NOTE Do not use power tools Otherwise piston damage may occur 8 Remove clutch plate collar worm gear and cir cular washer 9 Inspect clutch shoes for wear and s...

Page 43: ... turned further NOTE If starter assembly is installed untie tem porary knot holding starter grip tied in the first NOTE of 5 1 Inspecting clutch parts While hold ing starter grip turn clutch assembly anticlockwise until it cannot rotate further 3 Tighten clutch assembly with Clutch tool 897505 16133 L 5 2 Replacing clutch parts 1 Install clutch spring A to clutch shoes B 2 Set one arm of clutch hu...

Page 44: ...kshaft placing the hands c of collar C in cutouts g of clutch drum 5 Install sprocket H Install circular washer J facing flat side to sprocket H 6 Install new E ring K with smooth side to washer J Use a new E ring every time clutch as sembly is installed on crankshaft 7 Remove piston stopper and reinstall all removed parts flat side smoother side F G H J g K g J K ...

Page 45: ...EM CS 600 43 6 CHAIN BRAKE SYSTEM A Brake lever B Collar C Torsion spring D Brake cover E Brake connector F Spacer G Brake band H Spacer J Roller K Compression spring L Side plate M Crankcase G E F D C B A H K J M B L ...

Page 46: ...ury 1 Move brake lever A to chain brake engaging position 2 Remove sprocket guard B and brake lever NOTE Make sure that lever C is in engaging po sition before removing brake cover D otherwise compression spring may jump out 3 Loosen three screws securing brake cover D and remove brake cover 4 Remove guide plate E 5 Inspect all the brake parts for damage Replace them as required A B C D E ...

Page 47: ...e band and other parts refer to the above 1 on crankcase as shown Make sure the pin c1 of brake connector C is engaging with the groove G of crankcase 4 Slide in compression spring H to the end c2 of brake connector as sown 5 Install compression spring H in crankcase by pushing with longnose pliers etc as shown 6 Apply molybdenum grease on entire compres sion spring and other friction parts 7 Rein...

Page 48: ...ION SYSTEM CS 600 46 7 SAW CHAIN LUBRICATION SYSTEM A Oil cap B O ring C Connector D Oil tank vent E Crankcase e Oil tank F Oil strainer G Oil line H Grommet J Oil outlet line K Auto oiler assembly e A B F C D E G H K J ...

Page 49: ...e oil cap 2 Inspect oil cap for cracks and O ring A for cuts or damage Replace worn or damaged parts as re quired 3 Pull oil strainer B from oil tank using a wire hook C 4 Remove oil strainer B from oil line D and clean oil strainer in suitable solvent or replace if damaged A C B D B ...

Page 50: ... for discoloration or deformation Inspect gear e1 for wear and damage Inspect oil inlet e2 and outlet e3 for clog Replace as required 6 Connect Pressure tester 897803 30133 F to oil line D with pipe joint V186 000020 G 7 Tighten oil cap and apply pressure approx 9 8 kPa 0 1kgf cm2 1 4psi 8 Pressure should not drop If the pressure drops leakage may occur at oil cap oil cap O ring mat ing surface of...

Page 51: ...ent prevents a vacuum from forming in oil tank when chain oil in the tank is con sumed 1 Remove oil tank vent A using paper clip and clean it 2 Check that oil tank vent lips B are not hard or deformed Replace as required 3 Install oil tank vent A using suitable tool C as shown A C B A ...

Page 52: ...C of crankcase 6 Pass oil line A under brake band D and set clips E on the end of oil line and oil outlet line F 7 Connect oil line A and oil outlet line F to auto oiler assembly as shown 8 Pull out the other end a of oil line from oil cap hole 9 Reinstall auto oiler assembly to crankcase ad justing oil line length by pulling the other end a of oil line 10 Install oil strainer G to the other end a...

Page 53: ...0 06 in dia A push side wall of plug B through hole C to re move plug NOTE Plug may suddenly spring out of auto oiler assembly body 3 Pull out spring pin D from adjuster needle E with pliers 4 Pull out adjuster needle E from auto oiler body 5 Remove plunger F and spring G 6 Check plunger if worn or broken and spring if fatigued or broken D E A B C F G ...

Page 54: ...ng as shown 3 Bend steel wire and lift up V ring from the groove 4 Slowly rotate plunger while pulling V ring all the way out 5 Inspect V ring for hardness or damage 6 Oil inner wall a1 of V ring Hook V ring with steel wire as shown 7 Put V ring on the end B of plunger NOTE Lips a2 of V ring should face gear 8 Move V ring into the groove while carefully rotat ing plunger A B a1 a2 ...

Page 55: ...d b2 for smooth chain oil flow 4 Push in plunger with small screwdriver E and hold plunger in place with finger through the center hole F of auto oiler body Remove screwdriver E 5 Install adjuster needle G with spring H into oiler body 6 Press adjuster needle G to the bottom orient ing the flat surface g1 as shown 7 Tap in spring pin J into hole g2 of adjuster needle until spring pin bottoms 8 App...

Page 56: ...kcase C Ball bearing D Crankshaft assembly E Washer F Needle bearing G Snap ring H Piston pin J Piston K Piston ring L Intake bellows M Cylinder N Muffler O Muffler gasket P Arrestor screen Q Exhaust guide A B F C D E G H K J A B L M N O P E G Q ...

Page 57: ... port piston crown and muffler for carbon deposits NOTE Compression pressure varies with volume of compression gauge tip occupying cylinder combus tion chamber If gauge tip volume is considerably different from spark plug volume it is recommended to measure and note compression pressure of brand new engines as standard pressure in advance 8 2 Cleaning cooling air passages 1 Remove cleaner lid and ...

Page 58: ...4 Remove exhaust guides A and spark arrestor screen B from muffler 5 Remove carbon deposits from spark arrestor screen and exhaust guides If screen has heavy deposits replace with new one 6 Reinstall spark arrestor screen and exhaust guides to muffler 7 Reinstall muffler with new muffler gasket NOTE Before reinstalling muffler apply 2 stroke oil on muffler gasket surface and temporarily paste muff...

Page 59: ...ust port 5 Tighten upper 2 bolts of muffler 6 Remove decompressor F and install Plug 101115 37531 G and O ring 900720 00009 H as shown 7 Connect Pressure vacuum tester 91139 J to pulse line using provided pipe joint K 8 Apply pressure approx 50 kPa 0 5 bar 7 1 psi by the tester J 9 If the pressure drops leakage may occur 10 Leakage may occur from crankcase seam cylinder base oil seal and spark plu...

Page 60: ...xhaust port 4 Remove 4 bolts from cylinder base through holes C 5 Pull out cylinder upward pushing intake bellows B through the wall D 6 Inspect cylinder combustion chamber and clean with a plastic or wooden scraper if carbon is found NOTE Do not use metal tools or damage to cylin der wall may result 7 Inspect cylinder wall and replace with new one if plating is worn peeled away scored or exposing...

Page 61: ...ft cleaning brush A if carbon is found NOTE Do not use square end of broken piston ring when cleaning piston ring groove otherwise piston ring groove might be damaged 4 Remove snap ring B from both sides of piston pin using small screwdriver C NOTE Piston holder 897719 02830 D is recom mended 5 Push piston pin out from piston NOTE If piston pin is tight use Piston pin tool 897702 30131 E with adap...

Page 62: ...ntil flush with crank case surface B using Oil seal tool 897726 16431 C 8 8 Disassembling crankcase 1 Referring to 11 1 Disassembly chart remove necessary parts for crankcase disassembly 2 Remove 6 bolts A from crankcase 3 Install Crankcase tool 897502 19830 B with 3 bolts on one side of crankcase halves in the pic ture flywheel side is shown 4 Tighten bolt C to pull crankcase halves apart 5 Crank...

Page 63: ...ss D and appropriate thick ness metal plates E as shown 4 Tighten shaft A with wrench to remove ball bearing C Oil seal B remains in crankcase bore 5 Push out oil seal B with Oil seal tool 897714 12330 F 6 Coat bearing housing in crankcase with a lithium based grease 7 Set ball bearing with shaft A adapter G inner dia 15 mm outer dia 40 mm and boss D NOTE Set adapter G mating full flat side g to b...

Page 64: ... crankcase half 2 Insert crankshaft clutch end A into clutch side crankcase half B until properly seated NOTE If it is hard to insert crankshaft to crank case preheat ball bearing for easier installation 3 Put new crankcase gasket C on clutch side crankcase half B 4 Reassemble both crankcase halves together en suring that dowel pins b on clutch side crankcase half B are properly seated in holes on...

Page 65: ...cting rod as shown NOTE Piston pin guide B is included in Piston pin tool 897702 30131 3 Insert piston pin E in piston pushing out piston pin guide B using Piston pin tool 897702 30131 G and Piston holder 897719 02830 F 4 Install new snap rings to piston using small screwdriver and be sure that they are correctly seated in the grooves NOTE If it is hard to install snap rings modify screwdriver end...

Page 66: ...ll of cylin der 4 Install cylinder with intake bellows over piston ensuring that the exhaust side of cylinder should face front as shown 5 Pull intake bellows C through hole D with longnose pliers taking care not to damage intake bellows Set intake bellows correctly NOTE When installing cylinder it is convenient to use Piston holder 897719 02830 E to stabilize piston NOTE When installing piston in...

Page 67: ... SYSTEM CS 600 65 9 REAR HANDLE AND CONTROL SYSTEM A Rear handle B Spring pin C Torsion spring D Throttle trigger E Throttle lockout F Rear handle cover G Spring holder H Compression spring J Cushions D E G A B F C H G G H J ...

Page 68: ...cleaner lid air filter and cleaner case Disconnect fuel line pulse line throttle rod and choke knob from carburettor Remove carburettor from the unit 3 Remove three bolts A 4 Remove three bolts B on the other side of the unit 5 Remove collar C metal from intake bellows D rubber 6 Remove ground lead E and the end f of pulse line F from the unit C D F A B f E ...

Page 69: ... f of pulse line F to the unit Reassemble intake bel lows D with collar C to rear handle 12 Reassemble rear handle to the unit Reassem ble all related parts 9 2 Replacing throttle trigger 1 Loosen screw A and remove rear handle cover B 2 Inspect rear handle cover B and throttle lock out C for cracking or wear If damaged replace it as required 3 Push out spring pin D from rear handle using Spring p...

Page 70: ... inside handle 2 Hold throttle trigger F with torsion spring G in place and insert Spring pin tool 897724 01361 E from the other side of handle through the hole of throttle trigger 3 Lightly tap in spring pin D pushing out spring pin tool E 7 Hook the inside notch b of rear handle cover B on the tab h of rear handle H 8 Install rear handle cover B on rear handle H setting torsion spring G with thr...

Page 71: ...DE BAR MOUNTING SYSTEM CS 600 69 10 GUIDE BAR MOUNTING SYSTEM A Sprocket guard B Inner guide plate C Outer guide plate D Tensioner screw E Chain tensioner F Collar G Bevel gear H Bevel gear B E F H C D G A ...

Page 72: ... tensioner D on tensioner screw C setting flat side d upward 6 Set bevel gear E in collar G and insert ten sioner screw C with chain tensioner D in bevel gear with collar G 7 Install sub assembled tensioner screw in slot H of sprocket guard confirming engagement of bevel gear E and F 8 Reinstall outer guide plate B 10 2 Replacing guide bar stud 1 Remove oil cap and empty oil from tank 2 Remove inn...

Page 73: ...39 to 0 47 in D Thread M8 nut E clockwise onto stud Turn nut clockwise to pull stud through oil tank mounting hole The square head of the stud should seat against the oil tank wall parallel with inner ribs 5 Look into oil tank and check if square head F of the stud is properly seated inside crankcase If not install two nuts to the stud and secure them against each other 6 Turn nut G clockwise or n...

Page 74: ...essive Engine does not stop Oiler does not function Saw chain does not cut well INSPECTING Starter system Starter drum rope Ignition system Sparks Spark plug Spark plug cap coil Ignition switch Ignition coil Pole shoe air gaps Flywheel 2 2 3 2 3 3 3 7 3 4 3 6 3 8 3 9 3 10 Continued 15 Inspecting first 14 13 12 11 10 09 08 07 06 05 04 03 02 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Flywheel k...

Page 75: ... 4 6 1 8 2 8 3 1 2 8 1 8 4 8 4 8 8 8 6 Fuel tank line vent 4 3 to 4 5 INSPECTING 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 REFERENCES Carburettor diaphragms 4 12 Crankcase pulse passage 4 9 Throttle trigger 9 2 Fuel octane freshness purity 4 6 1 Others Chain brake Cushions Saw chain 6 1 6 2 9 1 Replace Sharpen 15 14 13 12 11 10 09 08 07 06 05 04 03 0...

Page 76: ... 6 Starter side oil seal 8 7 Flywheel 3 10 Carburettor 4 8 4 10 to14 Clutch side oil seal 8 7 Starter side ball bearing 8 9 Crankshaft 8 8 8 10 Clutch side ball bearing 8 9 Ignition coil 3 8 Front handle Rear handle 9 1 to2 Auto oiler 7 2 7 5 to7 Muffler 8 3 Starter assembly 2 1 Sprocket guard 2 1 5 1 6 1 Clutch drum 5 1 5 3 Air filter Cleaner case 4 1 4 3 Clutch assembly Worm gear 5 1 5 3 ...

Page 77: ...an inside 4 3 Muffler and exhaust port Clean 8 3 Starter system Inspect Repair 2 1 to 2 4 Oil tank Clean inside Oil strainer Clean Replace 7 1 Sprocket Inspect Replace 1 5 5 1 Guide bar Inspect Clean Chain brake Inspect Repair 6 1 6 2 Daily Inspecting in every services IMPORTANT Service intervals shown above are maximum Actual use and your experience will determine the frequency of required mainte...

Page 78: ... to 31 Ignition coil 4 14 17 19 to 21 Ignition switch 4 14 16 to 18 55 Ignition system 3 7 14 16 Ignition timing 3 7 Inlet needle valve 33 35 36 Intake bellows 4 54 57 58 64 66 67 Key flywheel 21 22 60 Limiter cap 7 29 to 31 L mixture needle 3 29 to 31 Maintenance guide 72 Metering diaphragm 34 36 Metering lever 3 33 to 35 37 Metering lever height 3 33 34 Minimum secondary voltage 3 7 Muffler 2 4 ...

Page 79: ...Printed in Japan 1001 ...

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