Echo CS-600 Service Manual
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Echo CS-600 Service Manual

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

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Summary of Contents for Echo CS-600

  • Page 1 CS-600 (Serial number: 36000001 and after) REVISED NOV. 2015 Ref. No. 401-31...
  • Page 2 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.

  • Page 3: Table Of Contents

    CS-600 TABLE OF CONTENTS Page Page 1 SERVICE INFORMATION ........2 5 CLUTCH SYSTEM ..........39 Specifi cations ...........2 Inspectng clutch parts ........40 Technical data ..........3 Replacing clutch parts ........41 Torque limits .............4 Installing clutch assembly .......41 Special repairing materials .......5 Service Limits ...........6 6 CHAIN BRAKE SYSTEM ........43...

  • Page 4: Service Information

    CS-600 SERVICE INFORMATION 1 SERVICE INFORMATION 1-1 Specifi cations 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 59.8 (3.649)

  • Page 5: Technical Data

    CS-600 SERVICE INFORMATION 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/cm ) (psi) 0.94 (9.6) (136) Ignition system Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028)

  • Page 6: Torque Limits

    CS-600 SERVICE INFORMATION 1-3 Torque limits Descriptions Size kgf•cm N•m in•lbf † Starter system Starter pawl Starter centre shaft screw Starter case Ignition system Magneto rotor (Flywheel) Ignition coil Spark plug Fuel system Carburettor Intake bellows LM10 Clutch Clutch hub †...

  • Page 7: Special Repairing Materials

    Starter centre shaft screw Loctite #222, ThreeBond 1342 or equivalent Grease Auto-oiler worm Clutch needle bearing Rubber cushion, inside Choke knob Lithium based grease or ECHO XTended Protection Lubricant Rewind spring Oil seal inner lips Starter centre shaft Brake cover Chain brake (metal contact part) Molybdenum grease (approx.

  • Page 8: Service Limits

    CS-600 SERVICE INFORMATION 1-5 Service Limits 5K253 5K083 5K084 5K081 5K082 5K016 5K025 5K254 5K173 5K174 5K181 5K181 5K097 5K097 mm (in) Description Cylinder bore When plating is worn and aluminium can be seen Piston outer diameter Min. 44. 90 (1.768) Piston pin bore Max.

  • Page 9: Special Tools

    CS-600 SERVICE INFORMATION 1-6 Special tools b = 4 mm b = 5 mm Part Number Description Reference G310-000050 Tachometer PET-304 Measuring engine speed to adjust carburettor X602-000340 Torx wrench (T27) Removing and installing bolt 897537-30130 Piston stopper Locking crankshaft rotation...

  • Page 10: Starter System

    CS-600 STARTER SYSTEM 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...

  • Page 11: Disassembling Starter Assembly

    CS-600 STARTER SYSTEM 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.

  • Page 12: Replacing Starter Rope

    CS-600 STARTER SYSTEM 2-2 Replacing starter rope 1. Pull out and untie knot (A). 2. Pull knot (B) to remove rope from rope reel (C). 3. When installing a new starter rope, singe both ends of the rope to prevent fraying.

  • Page 13: Assembling Starter

    CS-600 STARTER SYSTEM 2-3 Assembling starter 1. If rewind spring (A) is removed from spring case (B), rewind inside case as shown. c1 c2 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.
  • Page 14 CS-600 STARTER SYSTEM 2-3 Assembling starter (continued) 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.

  • Page 15: Replacing Starter Pawl

    CS-600 STARTER SYSTEM 2-4 Replacing starter pawl 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.

  • Page 16: Ignition System

    CS-600 IGNITION SYSTEM 3 IGNITION SYSTEM (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...

  • Page 17: Troubleshooting Guide

    CS-600 IGNITION SYSTEM 3-1 Troubleshooting guide Start Remedy Inspect S.T. Adjust pole shoe air gaps. Pole (Inspect flywheel magnet shoe air at the same time. Go to gaps Clean / A if OK.) Regap / Spark plug S.T. Replace. Flywheel Replace flywheel.

  • Page 18: Testing Spark

    CS-600 IGNITION SYSTEM 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.

  • Page 19: Inspecting Ignition Switch

    CS-600 IGNITION SYSTEM 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 fi n (B).

  • Page 20: Replacing Ignition Switch

    CS-600 IGNITION SYSTEM 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.

  • Page 21: Inspecting Ignition Coil Resistance

    CS-600 IGNITION SYSTEM 3-6 Inspecting ignition coil resistance 1. Remove cleaner lid and cylinder cover. 2. Connect one probe of Ohm-meter or multimeter to spark plug cap coil (A). 3. Connect the other probe to cylinder fin (B) to measure secondary coil resistance. Secondary coil resistance should be in the range of 1.7 to 2.2...

  • Page 22: Replacing Spark Plug Cap And Coil

    CS-600 IGNITION SYSTEM 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).

  • Page 23: Setting Pole Shoe Air Gaps

    CS-600 IGNITION SYSTEM 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 fl ywheel and ignition coil shoes. 2. Rotate fl ywheel until magnetic poles of fl ywheel face ignition coil shoes.
  • Page 24 CS-600 IGNITION SYSTEM 3-10 Inspecting fl ywheel and key (continued) 5. Remove starter pawls. Then set Puller 897501- 03938 (C) on fl ywheel as shown. 6. Tighten two nuts on the puller alternately to re- move fl ywheel. 7. Inspect woodruff key for damage or shearing.

  • Page 25: Fuel System

    CS-600 FUEL SYSTEM 4 FUEL SYSTEM ( A ) Fuel cap ( B ) O-ring ( C ) Connector ( D ) Fuel tank ( E ) Fuel tank vent ( F ) Fuel strainer ( G ) Pulse line...

  • Page 26: Inspecting Air Fi Lter

    CS-600 FUEL SYSTEM 4-1 Inspecting air fi lter 1. Close choke shutter. Remove cleaner lid and air fi lter. 2. Inspect the surface of air fi lter. If blocked with dirt or dust, remove the obstruction using brush. WARNING DANGER Wear eye protection when working with compressed air.

  • Page 27: Inspecting Fuel Tank And Line

    CS-600 FUEL SYSTEM 4-3 Inspecting fuel tank and line 1. Clean fuel tank inside as required. 2. Remove cleaner lid, air fi lter and cleaner case. 3. Disconnect fuel line (A) from carburettor. 4. Connect Pressure tester 897803-30133 (B) to fuel line.

  • Page 28: Inspecting And Replacing Tank Vent

    CS-600 FUEL SYSTEM 4-4 Inspecting and replacing tank vent NOTE: Tank vent prevents a vacuum from forming in fuel tank when fuel in fuel tank is being con- sumed. When pressure in fuel tank becomes too high, tank vent releases the pressure.
  • Page 29 CS-600 FUEL SYSTEM 4-4 Inspecting and replacing tank vent (continued) NOTE: Inspection using 897803-30133 If Pressure / vacuum tester 91139 is not available, tank vent can be inspected with Pressure tester 897803-30133 as follows. 1. Connect tank vent (A) to Pressure tester 897803-30133 (B).

  • Page 30: Replacing Fuel Line

    CS-600 FUEL SYSTEM 4-5 Replacing fuel line 1. Remove cleaner lid, air fi lter and cleaner case. 2. Disconnect fuel line (A) and pulse line (B) from carburettor. 3. Remove carburettor by disconnecting throttle rod (C) and choke knob (D).

  • Page 31: Adjusting Carburettor

    CS-600 FUEL SYSTEM 4-6 Adjusting carburettor 4-6-1 General adjustment rules A. Before adjustment, check the following items. 1. The correct spark plug must be clean and properly gapped. 2. The air fi lter element must be clean and properly installed.
  • Page 32 CS-600 FUEL SYSTEM 4-6 Adjusting carburettor (continued) 2. Screw limiter cap removal tool P/N 91019 anti- clockwise into centre hole of either limiter cap until tab of the limiter cap just comes out of the locating slot (Fig.1, Fig.2). NOTE: DO NOT REMOVE LIMITER CAP COM-...

  • Page 33: Adjusting Carburettor

    CS-600 FUEL SYSTEM 4-6-3 Adjusting carburettor 1. Start and warm engine for 1 minute alternating engine speed between WOT and idle every 5 seconds. Turn H mixture needle anticlockwise Throttle adjust screw until engine speed drops to approx. 11,500 rpm at WOT.

  • Page 34: Air Shutter

    CS-600 FUEL SYSTEM 4-7 Air shutter When it is cold weather and acceleration is poor, release air shutter. 1. Air shutter is 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.

  • Page 35: Testing Carburettor

    CS-600 FUEL SYSTEM 4-8 Testing carburettor NOTE: To perform this test, carburettor interior should be wet with fuel. If dry, a little leakage may occur from diaphragms and/or inlet needle seat. 1. Remove cleaner lid, air fi lter and cleaner case.

  • Page 36: Inspecting Crankcase Pulse Passage

    CS-600 FUEL SYSTEM 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 pulse passage is clogged.

  • Page 37: Inspecting Inlet Needle Valve

    CS-600 FUEL SYSTEM 4-11 Inspecting inlet needle valve 1. Remove metering lever (A) and pivot pin. Re- move spring (B) and inlet needle valve (C). 2. Inspect inlet needle valve if worn or sticky. Clean or replace as required. NOTE: Causes of fuel fl ooding from carburettor to...

  • Page 38: Inspecting Diaphragm

    CS-600 FUEL SYSTEM 4-12 Inspecting diaphragm 1. Inspect metering diaphragm (A) for hardening, distortion, or pin hole. Replace as required. 2. Remove pump cover (B), pump diaphragm (C) and pump gasket (D). 3. Inspect pump diaphragm (C) and replace if hardened or curled at valve tabs.

  • Page 39: Replacing Welch Plug

    CS-600 FUEL SYSTEM 4-13 Replacing Welch plug If engine does not run smoothly even after read- justing carburettor and inspecting carburettor parts, inspect low speed ports on carburettor as follows: 1. Remove metering lever and related parts to pro- tect them from damage.

  • Page 40: Installing Carburettor

    CS-600 FUEL SYSTEM 4-14 Installing carburettor 1. Connect throttle rod (A) to 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).

  • Page 41: Clutch System

    CS-600 CLUTCH SYSTEM 5 CLUTCH SYSTEM ( A ) Circular washer ( B ) Worm gear ( C ) Collar ( D ) Clutch plate ( E ) Clutch spring ( F ) Clutch shoe ( G ) Clutch hub...

  • Page 42: Inspectng Clutch Parts

    CS-600 CLUTCH SYSTEM 5-1 Inspecting clutch parts 1. Remove sprocket guard (A), cleaner lid (B) and air fi lter. NOTE: If starter assembly is installed, pull starter rope out about 20 cm (8 in), and make a temporary knot (C) to prevent starter damage when installing clutch assembly.

  • Page 43: Replacing Clutch Parts

    CS-600 CLUTCH SYSTEM 5-2 Replacing clutch parts 1. Install clutch spring (A) to clutch shoes (B). 2. Set one arm of clutch hub (C) to one clutch shoe. 3. Install other two clutch shoes on two arms as shown. 5-3 Installing clutch assembly 1.
  • Page 44 CS-600 CLUTCH SYSTEM 5-3 Installing clutch assembly (Continued) 4. Apply lithium-based grease to needle bearing (F). Install clutch drum (G) and needle bearing (F) on crankshaft, placing the hands (c) of collar (C) in cutouts (g) of clutch drum. 5. Install sprocket (H). Install circular washer (J), facing fl...

  • Page 45: Chain Brake System

    CS-600 CHAIN BRAKE SYSTEM 6 CHAIN BRAKE SYSTEM ( A ) Brake lever ( B ) Collar ( C ) Torsion spring ( D ) Brake cover ( E ) Brake connector ( F ) Spacer ( G ) Brake band...

  • Page 46: Disassembling Chain Brake

    CS-600 CHAIN BRAKE SYSTEM 6-1 Disassembling chain brake WARNING DANGER Wear eye protection and safety gloves when disassembling or assembling chain brake to protect eye and hand from injury. 1. Move brake lever (A) to chain brake engaging position. 2. Remove sprocket guard (B) and brake lever.

  • Page 47: Assembling Brake Parts

    CS-600 CHAIN BRAKE SYSTEM 6-2 Assembling brake parts 1. Set brake band (A) together with spacer (B), brake connector (C) and spacer (D), placing the notch (b) of spacer (B) as shown. Install roller (E) through brake band hole (a).

  • Page 48: Saw Chain Lubrication System

    CS-600 SAW CHAIN LUBRICATION SYSTEM 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...

  • Page 49: Inspecting Oil Cap And Strainer

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-1 Inspecting oil cap and strainer 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).

  • Page 50: Inspecting Auto-Oiler Assembly And Oil Line

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-2 Inspecting auto-oiler assembly and oil line 1. Referring to “5-1 Inspecting clutch parts”, re- move clutch parts. 2. Remove inner guide plate (A). 3. Remove two bolts (B). 4. Disconnect oil outlet line (C) and oil line (D) from auto-oiler assembly (E), and remove auto-oiler as- sembly.

  • Page 51: Inspecting Oil Tank Vent

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-3 Inspecting oil tank vent NOTE: Oil tank vent 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.

  • Page 52: Replacing Oil Line And Grommet

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-4 Replacing oil line and grommet 1. Pull out oil strainer from oil tank (Refer to “7-1 Inspecting oil cap and strainer”) and remove oil strainer from oil line. 2. Remove auto-oiler assembly from crankcase (Refer to “7-2 Inspecting auto-oiler assembly and...

  • Page 53: Disassembling Auto-Oiler Assembly

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-5 Disassembling auto-oiler assembly 1. Remove auto-oiler assembly from the unit. 2. Using a tool of approx. 1.5 mm (0.06 in) dia. (A), push side wall of plug (B) through hole (C) to re- move plug.

  • Page 54: Inspecting V-Ring

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-6 Inspecting V-ring 1. Inspect V-ring on plunger as follows. 2. Secure V-ring (A) and insert thin steel wire such as paper clip through the opening as shown. 3. Bend steel wire and lift up V-ring from the groove.

  • Page 55: Assembling Auto-Oiler Parts

    CS-600 SAW CHAIN LUBRICATION SYSTEM 7-7 Assembling auto-oiler parts 1. Clean inside of cylinder (C). D b2 2. Assemble spring (A) to plunger (B) as shown. 3. Coat plunger gear (b1) and spring (A) with grease and insert into cylinder (C) of auto-oiler body.

  • Page 56: Engine

    CS-600 ENGINE 8 ENGINE ( A ) Oil seal ( B ) Crankcase ( C ) Ball bearing ( D ) Crankshaft assembly ( E ) Washer ( F ) Needle bearing ( G ) Snap ring ( H ) Piston pin...

  • Page 57: Testing Cylinder Compression

    CS-600 ENGINE 8-1 Testing cylinder compression NOTE: Test cylinder compression when engine is cold. 1. Move ignition switch to STOP position. Then re- move spark plug. 2. Install Compression gauge 91037 (A) in spark plug hole and tighten by hand. Pull starter several times to stabilize reading on compression gauge.

  • Page 58: Inspecting Muffl Er And Exhaust Port

    CS-600 ENGINE 8-3 Inspecting muffl er and exhaust port 1. Remove cleaner lid and cylinder cover. 2. Remove muffl er with muffl er gasket. 3. Inspect cylinder exhaust port and clean the port using wooden or plastic stick if carbon is found.

  • Page 59: Testing Crankcase And Cylinder Seal

    CS-600 ENGINE 8-4 Testing crankcase and cylinder seal 1. Remove cleaner lid, air fi lter, cleaner case and cylinder cover. 2. Disconnect fuel line, pulse line, throttle rod and choke rod from carburettor, and remove carburet- tor from the unit.

  • Page 60: Inspecting Cylinder

    CS-600 ENGINE 8-5 Inspecting cylinder 1. Remove carburettor from the unit (Refer to “4-5 Replacing fuel line”). 2. Remove collar (A; metal) from intake bellows (B). 3. Remove muffl er with muffl er gasket (Refer to “8-3 Inspecting muffl er and exhaust port”).

  • Page 61: Inspecting Piston And Piston Ring

    CS-600 ENGINE 8-6 Inspecting piston and piston ring 1. Inspect piston ring and replace it if broken or scored, or if it exceeds service limits (Refer to “1-5”). 2. Inspect piston crown. Clean with fi ne sand pa- per, oil stone, or soft cleaning brush (A) if carbon is found.

  • Page 62: Replacing Oil Seal

    NOTE: Before removing fl 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.

  • Page 63: Replacing Ball Bearing And Oil Seal

    CS-600 ENGINE 8-9 Replacing ball bearing and oil seal 1. After disassembling crankshaft, check ball bear- ing for smooth rotation. If rough, replace it (them) with new one. NOTE: At the same time, replace oil seal with new one. 2. Remove ball bearing from crankcase half using Bearing tool 897701-14732 as follows.

  • Page 64: Assembling Crankshaft And Crankcase

    CS-600 ENGINE 8-9 Replacing ball bearing and oil seal (continued) 10. Apply lithium based grease or ECHO XTended Protection Lubricant on inner rubber lips of new oil seal. 11. Lubricate circumferences of new oil seal with high melting point grease.

  • Page 65: Installing Piston

    CS-600 ENGINE 8-11 Installing piston 1. Place piston over the small end of connecting rod, so that the arrow mark (A) on piston points front as shown. 2. Insert piston pin guide (B) stamped “11”, through piston, washers (C) and needle bearing (D) in con- necting rod as shown.

  • Page 66: Installing Piston Ring And Cylinder

    CS-600 ENGINE 8-12 Installing piston ring and cylinder 1. Install piston ring on piston, ensuring the end gaps of piston ring are properly positioned around locating pin (A) as shown. 2. Temporarily paste new cylinder gasket (B) on cylinder base with a little glue for easier installation of cylinder.

  • Page 67: Rear Handle And Control System

    CS-600 REAR HANDLE AND CONTROL SYSTEM 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...

  • Page 68: Replacing Cushions

    CS-600 REAR HANDLE AND CONTROL SYSTEM 9-1 Replacing cushions 1. Remove starter assembly from the unit (Refer to “2-1 Disassembling starter assembly”). 2. Remove cleaner lid, air fi lter and cleaner case. Disconnect fuel line, pulse line, throttle rod and choke knob from carburettor.

  • Page 69: Replacing Throttle Trigger

    CS-600 REAR HANDLE AND CONTROL SYSTEM 9-1 Replacing cushions (continued) 7. Remove rear handle from the unit. 8. Inspect cushions (G) for cracking or wear. If damaged, replace with new cushions as follows. 9. To remove cushions (G), pull by hand in direc- tion of arrows.
  • Page 70 CS-600 REAR HANDLE AND CONTROL SYSTEM 9-2 Replacing throttle trigger (continued) 5. Set torsion spring (G) on throttle trigger (F), placing an end of torsion spring in hole (f) of throt- tle trigger. 6. Install throttle trigger (F) with torsion spring (G) and insert spring pin (D) as follows.

  • Page 71: Guide Bar Mounting System

    CS-600 GUIDE BAR MOUNTING SYSTEM 10 GUIDE BAR MOUNTING SYSTEM ( A ) Sprocket guard ( B ) Inner guide plate ( C ) Outer guide plate ( D ) Tensioner screw ( E ) Chain tensioner ( F ) Collar...

  • Page 72: Replacing Chain Tensioner

    CS-600 GUIDE BAR MOUNTING SYSTEM 10-1 Replacing chain tensioner 1. Remove sprocket guard (A) from the unit. 2. Remove outer guide plate (B) from sprocket guard. Remove tensioner screw (C), chain tension- er (D) and bevel gears (E) (F) and collar (G).

  • Page 73: Installing Guide Bar Stud

    CS-600 GUIDE BAR MOUNTING SYSTEM 10-3 Installing guide bar stud 1. Apply adhesive (Loctite #609, ThreeBond 1373 or equivalent) to un-threaded part (A) of new guide bar stud. 2. Install new stud to the stud-hole of oil tank using a pair of tweezers (B).

  • Page 74: Maintenance Guide

    CS-600 MAINTENANCE GUIDE 11 MAINTENANCE GUIDE 11-1 Troubleshooting guide TROUBLE Engine does not crank. Engine does not start. Fuel leaks. Idling is not stable. Acceleration is poor. Engine stalls at high speed. Engine lacks power. Engine seizure / overheat Engine misfires.
  • Page 75 CS-600 MAINTENANCE GUIDE 11-1 Troubleshooting guide (continued) Inspecting first. INSPECTING REFERENCES Fuel system / Carburettor 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Air filter Fuel cap / strainer Carburettor adjustment Fuel tank / line / vent...

  • Page 76: Disassembly Chart

    CS-600 MAINTENANCE GUIDE 11-2 Disassembly chart Sprocket Cleaner guard (2-1,5-1,6-1) Clutch Air filter, Brake lever Spark plug Cylinder drum Cleaner case (2-1,6-1) (3-3) cover (5-1,5-3) (4-1,4-3) Starter assembly (2-1) Ignition coil (3-8) Clutch assembly, Carburettor Chain brake Muffler Front Worm gear...

  • Page 77: Service Intervals

    CS-600 MAINTENANCE GUIDE 11-3 Service Intervals Intervals Inspecting point Service Reference 3 months 6 months Daily 100 hours 300 hours Screws and bolts * Retighten / Replace Air fi lter Clean Inspect / Replace Carburettor Inspect / Repair 4-8 to 4-14...

  • Page 78: Index

    CS-600 INDEX Adhesive 5, 71 Exhaust guide 54, 56 Piston pin 6, 7, 54, 59, 63 Air fi lter 23 to 26, 28 to 30, 33, 40, 57, Exhaust port, cylinder 7, 29, 55 to 58, Piston ring 6, 54, 55, 59, 64...
  • Page 79 Printed in Japan 1001...

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