Echo shindaiwa CS-501SX Service Manual Download Page 75

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MAINTENANCE GUIDE

CS-501SX, CS-501SXH
501sx

11-1 Disassembly chart

Crankcase,

(8-5, 8-6, 8-8)

Cylinder, Piston ring

Air filter

(4-1)

Cushions

(9-2)

Rear

handle

(9-2)

Clutch side

oil seal

(8-7)

Clutch side

ball bearing

(8-9)

Cleaner

lid

Sprocket

guard

(2-1,5-1,6-1)

Clutch

drum

(5-1,5-3)

Muffler

(8-3)

Clutch assembly,

Worm gear

(5-1,5-3)

Auto-oiler

(7-2)

Brake lever

(6-1,7-2)

Brake cover

(6-1,7-2)

Crankshaft

assembly

(8-8,8-10)

Piston

(8-6)

Starter side
ball bearing

(8-9)

Starter side

oil seal

(8-7)

Flywheel

(3-10)

Ignition

coil

(3-8)

Carburetor

(4-8,4-10 to14)

Cylinder

cover

Starter

assembly

(2-1)

Spark plug

(3-3)

Brake band

(6-2)

11 MAINTENANCE GUIDE

Summary of Contents for shindaiwa CS-501SX

Page 2: ...rences 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 t...

Page 3: ...pecting inlet needle valve 33 4 12 Inspecting diaphragm 33 4 13 Replacing Welch plug 34 4 14 Installing carburetor 35 5 CLUTCH SYSTEM 36 5 1 Inspectng clutch parts 37 5 2 Replacing clutch parts 38 5 3...

Page 4: ...2 Carburetor Type Diaphragm horizontal draft Model Walbro WT 1139 Venturi size Throttle bore mm in 13 5 15 85 0 531 0 624 Ignition Type CDI Capacitor discharge ignition system Spark plug NGK BPMR8Y Ex...

Page 5: ...um idle speed 2 3 Set idle maximum speed w TAS r min 3 500 4 Set idle speed by turning L mixture needle CCW r min 2 700 5 Confirm H mixture needle position before WOT setting Turn H mixture needle CCW...

Page 6: ...5 50 70 5 7 45 60 Cushion on Front handle M5 20 30 2 3 18 25 Front handle M5 40 55 4 5 5 35 48 M4 30 45 3 4 5 25 40 Rear handle M side M5 40 55 4 5 5 35 48 assembly D side M5 40 55 4 5 5 35 48 Handle...

Page 7: ...n B Piston outer diameter Min 43 87 1 727 C Piston pin bore Max 11 025 0 4341 D Piston ring groove Max 1 6 0 063 E Piston ring side clearance Max 0 1 0 004 F Piston pin outer diameter Min 10 98 0 4323...

Page 8: ...l Installing oil seals and clutch plate 13 897800 79931 Spark tester Checking ignition system 14 897803 30133 Pressure tester Testing carburetor and crankcase leakage 15 Y089 000094 Carburetor adjustm...

Page 9: ...SX CS 501SXH 501sx 7 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 L Needle grommet F Rope reel...

Page 10: ...screws and remove starter assem bly A from unit 2 Pull out starter rope about 30 cm 12 in and hold rope reel B by hand Loop excess rope in rope reel notch b as shown 3 Rotate rope reel B counterclock...

Page 11: ...and pass the rope through hole of rope reel then press the knot D into recess as shown 4K287 3 When installing a new starter rope singe both ends of the rope to prevent fraying 5 Pass the other end o...

Page 12: ...hook a of rewind spring NOTE Apply lithium based grease ECHO XTend ed Protection Lubricant or Red Armor Lubricant on around startet shaft c2 of starter case C if dry 4 Check for proper engagement of r...

Page 13: ...nal 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 r...

Page 14: ...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...

Page 15: ...IGNITION SYSTEM CS 501SX CS 501SXH 501sx 13 3 IGNITION SYSTEM A Flywheel E Spark plug cap B Ignition coil F Switch lead C Spark plug G Ignition switch D Spark plug cap coil A B C D E G F...

Page 16: ...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 O...

Page 17: ...ittent 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...

Page 18: ...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 A B A B B E C...

Page 19: ...r fin B to measure secondary coil resistance Secondary coil resistance should be in the range of 2 5 to 2 9 k 4 If the meter reading indicates infinite resistance remove spark plug cap and spark plug...

Page 20: ...etting pole shoe 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...

Page 21: ...age may occur 4 Remove 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 ign...

Page 22: ...ler alternately 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 int...

Page 23: ...SX CS 501SXH 501sx 21 4 FUEL SYSTEM A Fuel cap B O ring C Fuel tank vent D Fuel tank E Fuel strainer F Fuel line G Pulse line H Carburetor J Carburetor elbow K Gasket L Air filter M Cleaner lid A B D...

Page 24: ...sh away with non inflammable solvent detergent WARNING DANGER Wear eye protection when working with compressed air Eye damage can occur from flying particles A D C 4 2 Inspecting fuel cap and fuel str...

Page 25: ...inch fuel line D with 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 ps...

Page 26: ...to 9 1 Replacing cushions and connect Pressure vac uum tester 91149 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 ps...

Page 27: ...ge gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valve in tank vent as sembly as shown Damage to valve will occur 4 Remove cap C of tank vent and clean spo...

Page 28: ...fuel cap and remove fuel strainer E and clip F from fuel line A 6 Pull out fuel line A in direction of arrows Re place them if defective 7 Set clip F on new fuel line A and connect fuel strainer E 8 I...

Page 29: ...A Replace them if defective Refer to 4 4 Inspecting and replacing tank vent 3 Connect pipe B to fuel tank vent A 4 Insert pipe b to hole c1 on rear handle as sembly C Pass pipe B through notch c2 on...

Page 30: ...t run correctly after this adjustment proceed to the next step 2 2 4 6 2 Initial setting Throttle adjust screw L mixture needle and H mixture needle Tools Required Small flat head screwdriver with 2 5...

Page 31: ...ine 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 12 500 r...

Page 32: ...1 Air shutter is located in cylinder cover A 2 Picture shows normal position sun mark of air shutter B 3 Reverse air shutter B to open position snow man mark to open air duct and introduce warm air f...

Page 33: ...ove 49 kPa 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 fi...

Page 34: ...lever height 1 Remove carburetor 2 Remove four screws A metering diaphragm cover B metering diaphragm C and gasket D 3 Inspect metering lever E height by Metering lever gauge 897563 19830 F Metering l...

Page 35: ...or 2 Spring is under dimple of metering lever 3 metering lever fork is holding inlet needle valve A B C 4 12 Inspecting diaphragm 1 Inspect metering diaphragm A for hardening distortion or pin hole Re...

Page 36: ...related 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...

Page 37: ...or 1 Connect fuel line A and pulse line B to carbu retor as shown 2 Connect throttle rod C to carburetor 3 Connect choke rod D with choke grommet E to carburetor 4 Secure carburetor F and carburetor e...

Page 38: ...CS 501SXH 501sx 36 5 CLUTCH SYSTEM A Crankcase B Collar C Worm gear D Clutch spring E Clutch hub F Clutch shoe G Clutch assembly H Needle bearing J Clutch drum K Sprocket L Circular washer M Nut G C...

Page 39: ...op crankshaft rotation 4 Rotate clutch assembly clockwise by hand until it cannot be rotated further 5 Remove nut D circular washer E and sprock et F 6 Remove clutch drum G with needle bearing in side...

Page 40: ...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 furt...

Page 41: ...e to needle bearing E Install clutch drum F and needle bearing E on crankshaft placing the hands b of worm gear B in cutouts f of clutch drum 5 Install sprocket G Install circular washer H facing flat...

Page 42: ...S J G M B D C K L N P F H R A Brake lever B Collar C Torsion spring D Brake seal plate E Brake band F Spring pin G Coil spring H Brake connector J Brake cover K Sprocket guard plate L Sprocket guard p...

Page 43: ...e brake lever A to chain brake engaging position 2 Remove sprocket guard B 3 Remove screw C and two bolts D to remove sprocket guard plate E and spike F 4 Remove three bolts G and brake cover H 5 Insp...

Page 44: ...Make sure the pin B in brake band A is engaging with the groove f1 of crankcase 3 Install boss G through hole c3 of brake con nector C 4 Set brake lever H with bolt J 5 Set the end of coil spring E on...

Page 45: ...N SYSTEM CS 501SX CS 501SXH 501sx 43 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 Auto oiler assembly J Oiler cover...

Page 46: ...1 Remove 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...

Page 47: ...using flat head screw driver D 3 Remove brake lever E coil spring C brake band F oiler cover G and related parts 4 Remove two bolts H and auto oiler assembly J 5 Inspect auto oiler assembly J for disc...

Page 48: ...vent NOTE Oil tank vent prevents a vacuum from forming in oil tank when chain oil in the tank is con sumed 1 Inspect oil tank vent A for clog or deformation Replace as requied 2 Remove oil tank vent A...

Page 49: ...C E A Oil seal B Crankcase C Ball bearing D Crankshaft assembly E Washer F Needle bearing G Snap ring H Piston pin J Piston K Piston ring L Cylinder M Muffler N Muffler gasket P Arrestor screen Q Exh...

Page 50: ...st 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 di...

Page 51: ...ving muffler 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...

Page 52: ...rt 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 91149 J to pulse line using provided p...

Page 53: ...bustion 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 5 Inspect cylinder wall and replace with new one if pla...

Page 54: ...soft 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...

Page 55: ...melting point grease 5 Push in new oil seal A until flush with crank case surface B using Oil seal tool X646 000360 C B C A A A B 8 8 Disassembling crankcase 1 Referring to 11 1 Disassembly chart rem...

Page 56: ...ows 3 Set shaft A through oil seal B and ball bearing C with boss D as shown 4 Tighten shaft A with wrench to remove ball bearing C and Oil seal B 5 Coat bearing housing in crankcase with a lithium ba...

Page 57: ...ng surface of each 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 fo...

Page 58: ...ng 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 holde...

Page 59: ...der gasket B is to wards brake lever side 3 Apply oil to piston ring and internal wall of cylin der 4 Install cylinder C with intake bellows bellows holder and intake insulator with over piston ensur...

Page 60: ...SYSTEM CS 501SX CS 501SXH 501sx 58 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 Grip H Cushions J Cushion ca...

Page 61: ...L SYSTEM on previous page 2 Remove a bolt B four cushion caps A four bolts C under cushion caps A and rear handle from unit 3 Inspect cushions D for cracking and wear If damaged replace with new cushi...

Page 62: ...groove e to pro jection f of the boss F 10 Apply adhesive Loctite 422 or equivalent to the base of cushion E 11 Inspect cushions G for cracking or wear If damaged replace with new cushions as follows...

Page 63: ...rip B rear handle cover C and throttle lockout D 2 Inspect grip B rear handle cover C and throt tle lockout D for cracking or wear If damaged replace it as required 3 Push out spring pin E from rear h...

Page 64: ...Align spring pin E and the hole of throttle trigger G with torsion spring H and insert spring pin E in the hole of throttle trigger G 3 Lightly tap in spring pin E using spring pin tool 897724 01361...

Page 65: ...x 63 9 3 Service hint for heated handle CS 501SXH only A Front handle assembly with heater B Band C Handle cover D Heater switch E Nut F Rear handle cover G Rear handle H Cushion J Rear handle heater...

Page 66: ...other probe to heater switch lever E or a clean ground as shown 5 Tester should show that the circuit is in conduct ing state 6 If stator assembly is defective replace with a new one Refer to 9 3 2 R...

Page 67: ...itch termi nal C as shown 4 Tester should show that the circuit is in conduct ing state 5 If rear handle heater is defective replace with a new one Refer to 9 3 3 Replacing rear handle heater Inspecti...

Page 68: ...tor lead coupler B remove carburetor and carburetor elbow and check where the lead is connected to 4 Install piston stopper X644 000020 C into spark plug hole by hand to stop crankshaft rota tion 5 Re...

Page 69: ...bly and connect stator lead coupler B 11 Reinstall disassembled parts 9 3 3 Replacing rear handle heater 1 Remove air cleaner cover air filter and handle cover 2 Remove screw A Remove handle grip B an...

Page 70: ...handle heater 6 Pass the rear handle heater lead K as shown 7 Pass the rear handle heater lead L as shown 8 Reinstall boots J to each lead terminal as shown 9 Connect rear handle heater lead K to heat...

Page 71: ...dle cover E as shown 11 Insert the tab d of handle grip D into rear handle and install handle grip D as shown 12 Reinstall disassembled parts E D 9 3 4 Replacing heater switch 1 Remove air cleaner cov...

Page 72: ...501SX CS 501SXH 501sx 70 A B C E 10 GUIDE BAR MOUNTING SYSTEM A Sprocket guard B Inner sprocket guide plate C Outer sprocket guide plate D Tensioner screw E Chain tensioner F Collar G Bevel gear H Bev...

Page 73: ...nstall bevel gear G into sprocket guard 5 Screw chain tensioner E on tensioner screw D 6 Insert bevel gear F in tensioner screw D with chain tensioner E 7 Install sub assembled tensioner screw in slot...

Page 74: ...mm 0 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...

Page 75: ...8 9 Cleaner lid Sprocket guard 2 1 5 1 6 1 Clutch drum 5 1 5 3 Muffler 8 3 Clutch assembly Worm gear 5 1 5 3 Auto oiler 7 2 Brake lever 6 1 7 2 Brake cover 6 1 7 2 Crankshaft assembly 8 8 8 10 Piston...

Page 76: ...ive 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...

Page 77: ...10 4 11 4 13 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 Carbur...

Page 78: ...ct Repair 3 5 Fuel tank Clean 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...

Page 79: ...MEMORANDUM CS 501SX CS 501SXH 501sx 77...

Page 80: ...Published by YAMABIKO Corp Tokyo Japan 1902...

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Echo shindaiwa CS-501SX, Service Manual

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