Echo CS-271T Service Manual
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Echo CS-271T Service Manual

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CS-271T
Ord. No. 401-37

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Summary of Contents for Echo CS-271T

  • Page 1 CS-271T Ord. No. 401-37...
  • Page 2 INTRODUCTION This service manual contains information for ser- vice and maintenance of ECHO CHAIN SAW, model CS-271T. 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-271T TABLE OF CONTENTS Page Page 1 SERVICE INFORMTION........................2 2 STARTER SYSTEM.........................7 3 IGNITION SYSTEM........................13 4 FUEL SYSTEM..........................22 5 CLUTCH SYSTEM........................36 6 CHAIN BRAKE SYSTEM......................39 7 SAW CHAIN LUBRICATION SYSTEM..................43 8 ENGINE............................50 9 TOP HANDLE AND CONTROL SYSTEM ..................60 10 GUIDE BAR MOUNTING SYSTEM....................62...

  • Page 4: Service Informtion

    CS-271T SERVICE INFORMATION 1 SERVICE INFORMATION 1-1 Specifications Model CS-271T Dimensions Length* mm(in) 257 (10.12) Width mm(in) 228 (8.98) Height mm(in) 210 (8.27) Dry weight* kg(lb) 3.0 (6.6) YAMABIKO, air-cooled, two-stroke, single cylinder Engine Type gasoline engine Rotation Clockwise as viewed from the output end Displacement 26.9 (1.641)
  • Page 5 CS-271T SERVICE INFORMATION Oregon Saw chain 91VG as option Cutting devices Guide bar Part No. 10A0CD3740 12A0CD3745 Called length Gauge 0.050 Saw chain Number of drive links Pitch Gauge 0.050 1-2 Technical data Engine Idling speed 3,200 +/- 300 Wide open throttle speed*...
  • Page 6 Thread locking sealant Ignition coil ® ON-OFF switch Loctite #242, ThreeBond #1324 or equivalent Clutch needle bearing Rear handle cushion Lithium based grease or ECHO XTended Collar Grease Protection Lubricant Starter grip rope guide Oil seal lip Chain brake (metal contact part)
  • Page 7 CS-271T SERVICE INFORMATION 1-5 Service Limits 5K177 5K083 5K084 5K081 5K082 5K016 5K025 5K178 5K190 5K191 5K173 5K174 5K097 Description mm (in) A Cylinder bore When plating is worn and aluminum can be seen Piston outer diameter Min. 34. 91 (1.374) Piston pin bore Max.
  • Page 8 CS-271T SERVICE INFORMATION 1-6 Special tools 16, 17 Part Number Description Reference 900303 Tachometer PET-304 Measuring engine speed 89561279920 L-hex wrench (3 mm) Removing and installing hex. socket bolt (M4) 89561079920 L-hex wrench (4 mm) Removing and installing hex. socket bolt (M5)

  • Page 9: Starter System

    (E) until accumulated energy is enough to overcome compression pressure in cylinder. NOTE: Pawl catcher (F) of CS-271T has an extended collar (f) to provide smooth power spring 6. When accumulated energy in power spring (E) (E) action and prevent power spring deformation.
  • Page 10 CS-271T STARTER SYSTEM 2-1 Disassembling starter assembly 1. Remove three screws and remove starter as- sembly (A) from unit. 2. Pull out starter rope about 30cm (12in) and hold rope reel (B) by hand. Loop excess rope in rope reel notch (b) as shown.
  • Page 11 CS-271T 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. 4. Make a knot (D) at end of starter rope and pass the rope through hole of rope reel, then press the knot (D) into recess as shown.
  • Page 12 CS-271T STARTER SYSTEM 2-3 Assembling starter 1. If rewind spring (A) is unwound from rewind spring case (B), wind the spring inside case as shown. 2. Carefully install rewind spring case assembly (C) on starter case, matching hole (c) with post (D).
  • Page 13 CS-271T STARTER SYSTEM 2-3 Assembling starter (continued) 5. Install power spring (G), engaging hook (g1) with rope reel groove (f2). 6. Install pawl catcher (H), engaging hole (h) with power spring top end hook (g2). NOTE: Make sure pawl catcher and rope reel have ID mark “838”...
  • Page 14 CS-271T 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 clean rope (E) in spark plug hole (F) to stop crankshaft rotation and remove bolt easily.

  • Page 15: Ignition System

    CS-271T IGNITION SYSTEM 3 IGNITION SYSTEM (A) Flywheel (E) Spark plug cap (B) Ignition coil (F) Switch lead (C) Spark plug (G) Ground lead (D) Spark plug cap coil (H) Ignition switch...
  • Page 16 CS-271T 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 17 CS-271T IGNITION SYSTEM 3-2 Testing spark 1. Remove air filter cover. Remove spark plug cap from spark plug. 2. C o n n e c t s p a r k p l u g c a p t o s p a r k t e s t e r 99051130023 (A), and connect spark tester lead (B) on spark plug as shown.
  • Page 18 CS-271T IGNITION SYSTEM 3-4 Inspecting ignition switch 1. Remove dust cover (A). 2. Disconnect ignition switch terminal (B) from pri- mary lead terminal (C). 3. Connect one probe of Ohm-meter or multi-meter to ignition switch terminal (B). Connect the other probe to another ignition switch terminal (D).
  • Page 19 CS-271T IGNITION SYSTEM 3-5 Replacing ignition switch 1. Remove sprocket guard. 2. Remove cushion cap (A) by hooking hole (a) with small hexagon wrench (B) etc., and remove screw inside. 3. Remove four screws (C). 4. Remove top handle lid (D). 5. Disconnect terminals (e) and remove ignition switch (E).
  • Page 20 CS-271T IGNITION SYSTEM 3-6 Inspecting ignition coil resistance and primary lead 1. Remove air cleaner cover and starter assembly. 2. Connect one probe of Ohm-meter or multimeter to spark plug cap coil in spark plug cap (A). 3. Connect the other probe to ignition coil core (B) to measure secondary coil resistance.
  • Page 21 CS-271T IGNITION SYSTEM 3-7 Replacing spark plug cap and coil 1. Disconnect spark plug cap (A) from spark plug. 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 tension lead.
  • Page 22 CS-271T 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 flywheel and ignition coil shoes. 2. Rotate flywheel until magnetic poles of flywheel face ignition coil shoes.
  • Page 23 CS-271T IGNITION SYSTEM 3-10 Inspecting flywheel and key (continued) 6. Remove starter pawls. Then set puller 89750103938 (C) on flywheel as shown. 7. Tighten two nuts on the puller alternately to re- move flywheel. 8. Inspect woodruff key for damage or shearing.

  • Page 24: Fuel System

    CS-271T FUEL SYSTEM 4 FUEL SYSTEM ( A ) Fuel cap ( B ) O-ring ( C ) Connector ( D ) Fuel tank vent ( E ) Fuel tank ( F ) Fuel strainer ( G ) Fuel lines...
  • Page 25 CS-271T FUEL SYSTEM 4-1 Inspecting air filter 1. Close choke shutter. Remove air cleaner cover and air filter. 2. Inspect air filter. If blocked with dirt or dust, re- move the obstruction with compressed air. WARNING DANGER Wear eye protection when working with compressed air. Eye damage can occur from...
  • Page 26 CS-271T FUEL SYSTEM 4-3 Inspecting fuel tank and line 1. Clean fuel tank inside as required. 2. Remove dust cover, disconnect fuel line (A) with joint (B) and connect pressure tester 89780330133 (C) to fuel line. 3. Remove fuel cap and pull out fuel strainer (D) from fuel tank.
  • Page 27 CS-271T 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. 1. Remove starter assembly. Remove tank vent (A) from fuel tank and connect pressure tester 91024 (B).
  • Page 28 CS-271T FUEL SYSTEM 4-4 Inspecting and replacing tank vent (continued) NOTE: Inspection using 897803-30133 If pressure tester 91024 is not available, tank vent can be inspected with pressure tester 89780330133 as follows. 1. Connect tank vent (A) to pressure tester 89780330133 (B). 2. Apply pressure approx. 50 kPa (0.5 kgf/cm ) (7 psi).
  • Page 29 CS-271T FUEL SYSTEM 4-5 Replacing purge bulb NOTE: Purge bulb can be replaced even if carbu- retor is assembled. 1. Disconnect lines from purge bulb. 2. Press leg (A) of purge bulb with screwdriver to remove purge bulb from top handle. 3. Push new purge bulb into top handle.
  • Page 30 CS-271T FUEL SYSTEM 4-7 Adjusting carburetor 4-7-1 General adjusting rules A. Before 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.
  • Page 31 CS-271T FUEL SYSTEM 4-7 Adjusting carburetor (continued) 2. Screw 2.5 mm limiter cap removal tool P/N 89801 CCW into center hole of limiter cap until tab of the limiter cap just comes out of the locating slot. NOTE : DO NOT COMPLETELY REMOVE LIMIT-...
  • Page 32 CS-271T FUEL SYSTEM 4-7 Adjusting carburetor (continued) 4-7-3 Adjusting carburetor 1. Start and warm engine for 100 seconds alter- nating engine speed between WOT and idle every Idle adjust screw 5 seconds. Turn H mixture needle CCW until en- gine speed drops to approx. 11,400 rpm at WOT.
  • Page 33 CS-271T FUEL SYSTEM 4-8 Testing carburetor NOTE: To perform this test, carburetor interior should be wet with fuel. If dry, a little leakage may occur. 1. Remove dust cover. 2. Disconnect fuel line (A) from joint (B). Connect pressure tester 89780330133 (C) to joint (B).
  • Page 34 CS-271T FUEL SYSTEM 4-9 Inspecting crankcase pulse passage 1. Drop a little oil in pulse hole (A) on intake bel- lows. 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 35 CS-271T 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 flooding from carburetor to...
  • Page 36 Otherwise, main nozzle check valve and inlet needle valve spring may be damaged by the compressed air. NOTE: CS-271T uses an alcohol resistant meter- ing diaphragm (A). The alcohol resistant metering round corner diaphragm has both a square tab (a1) and sharper triangle tab corner (a2) as ID mark.
  • Page 37 1. Install fuel inlet (A) and pulse passage nipple (B) as shown. 2. Connect throttle rod (C) to carburetor. NOTE: Early production CS-271T used sealant on mating surface between carburetor and intake bel- lows. Use of sealant is no longer required on any CS-271T after confirmation test.

  • Page 38: Clutch System

    CS-271T CLUTCH SYSTEM 5 CLUTCH SYSTEM ( A ) Clutch assembly ( B ) Clutch plate ( C ) Clutch drum ( D ) Needle bearing ( E ) Collar ( F ) Worm gear ( G ) Circular washer...
  • Page 39 CS-271T CLUTCH SYSTEM 5-1 Inspecting clutch parts 1. Remove sprocket guard (A) and air cleaner cov- er (B). 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 40 CS-271T CLUTCH SYSTEM 5-2 Replacing clutch parts 1. Install clutch springs (A) to clutch shoes (B). NOTE : Make sure to have ends of clutch springs (A) face clutch hub (C) 2. Set one arm of clutch hub (C) to one clutch shoe (B).

  • Page 41: Chain Brake System

    CS-271T CHAIN BRAKE SYSTEM 6 CHAIN BRAKE SYSTEM ( A ) Brake lever ( B ) Collar ( C ) Spacer ( D ) Sprocket guard ( E ) Compression spring ( F ) Spacer ( G ) Brake band...
  • Page 42 CS-271T 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. Remove sprocket guard from the unit. 2. Move brake lever (A) to chain brake engaging position. 3. Remove bolt (a) and remove brake lever (A) from sprocket guard. NOTE: Make sure that brake connector (B) is in engaging position before removing brake cover (C), otherwise compression spring may jump out.
  • Page 43 CS-271T CHAIN BRAKE SYSTEM 6-2 Assembling brake parts 1. Install pin (A) through brake band hole (b). 2. Install brake band (B) with pin (A) in sprocket guard as shown in the left picture. Set brake con- nector (C), spacer (D) and spacer (E), placing the notch (d) of spacer (D) as shown.
  • Page 44 CS-271T CHAIN BRAKE SYSTEM 6-3 Assembling brake lever 1. Install torsion spring (A) setting shorter end (a1) in the groove (B) of sprocket guard as shown. 2. Set brake lever (C) on sprocket guard, installing torsion spring longer end (a2) inside brake lever by bending with driver etc.

  • Page 45: Saw Chain Lubrication System

    CS-271T SAW CHAIN LUBRICATION SYSTEM 7 SAW CHAIN LUBRICATION SYSTEM ( A ) Oil cap ( B ) O-ring ( C ) Connector ( D ) O-ring ( E ) Oil tank vent ( F ) Engine cover ( f ) Oil tank...
  • Page 46 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-2 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 starter assembly. 2. Remove O-ring (A). 3. Remove oil tank vent (B) using paper clip and clean it.
  • Page 47 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-3 Inspecting oil line 1. Remove sprocket guard. 2. Remove screw (A) and remove chain catcher (B) and sprocket guard plate (C). 3. Disconnect oil line (D) and clip from auto-oiler assembly. 4. Connect pressure tester 89780330133 (E) to oil line (D).
  • Page 48 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-4 Replacing oil line and grommet 1. Remove sprocket guard plate from the unit (Refer to “7-3 Inspecting oil line”). 2. Disconnect oil line (A) from auto-oiler assembly (B) together with clip (C). 3. Remove clip (C) from oil line (A).
  • Page 49 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-5 Disassembling auto-oiler assembly 1. Remove auto-oiler assembly from the unit. 2. Tap 5-mm (M5 - Pitch 0.8mm) thread in the hole of plug (A). 3. Screw the bolt (B) of puller 89750103938 into the hole of plug (A), and connect PTO shaft puller 89760323030 (C) as shown.
  • Page 50 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-6 Replacing V-ring 1. Inspect V-ring on plunger for hardness or dam- age. Replace as follows if required. 2. Secure V-ring (A) and insert thin steel wire such as paper clip through the opening as shown.
  • Page 51 CS-271T SAW CHAIN LUBRICATION SYSTEM 7-7 Assembling auto-oiler parts 1. Assemble spring (A) to plunger (B) as shown. 2. Coat plunger gear (b) and spring (A) with grease and insert into cylinder (C) of auto-oiler body. NOTE: Do not apply grease on V-ring (D) and plunger shaft end (E), because these are a part of chain oil passage.

  • Page 52: Engine

    CS-271T ENGINE 8 ENGINE ( A ) Cylinder (Upper crankcase) ( B ) Crankcase (Lower crankcase) ( C ) Crankshaft assembly ( D ) Ball bearing ( E ) Oil seal ( F ) Piston ring ( G ) Snap ring...
  • Page 53 CS-271T ENGINE 8-1 Testing cylinder compression NOTE: Test cylinder compression when engine is cold. 1. Move ignition switch to STOP position. Then re- move air cleaner cover and 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 54 CS-271T ENGINE 8-3 Inspecting muffler and exhaust port 1. Remove muffler cover. 2. Remove exhaust heat shield (A) and muffler (B) with muffler gasket (C). 3. Inspect cylinder exhaust port and clean the port using wooden or plastic stick if carbon is found. NOTE: When cleaning exhaust port, always posi- tion piston at Top Dead Center (TDC) to prevent carbon from entering cylinder.
  • Page 55 CS-271T ENGINE 8-4 Testing crankcase and cylinder sealings 1. Remove air cleaner case. 2. Remove carburetor from the unit. 3. To seal intake port and crankcase pulse pas- sage, install pressure rubber plug 89782616131 (A) and pressure plate 89782716131 (B) with M5 bolts (C) of length 15-20 mm (0.6-0.8 in).
  • Page 56 CS-271T ENGINE 8-5 Removing engine block 1. Remove sprocket guard, clutch assembly and auto-oiler assembly (Refer to “5-1 Inspecting clutch parts”). 2. Remove air cleaner cover, air filter case and carburetor. 3. Remove flywheel (Refer to “3-10 Inspecting fly- wheel and key”).
  • Page 57 CS-271T ENGINE 8-6 Inspecting cylinder 1. Remove 4 bolts securing crankcase. 2. Gently tap both crankshaft ends using plastic mallet to remove lower crankcase with crankshaft and piston assembly. 3. Inspect cylinder combustion chamber and clean with a plastic or wooden scraper if carbon is found.
  • Page 58 CS-271T ENGINE 8-8 Inspecting crankcase and crankshaft 1. Clean crankcase. Replace as a set of cylinder and crankcase if damaged. 2. Completely remove sealant residue on mating surfaces and bearing bore of crankcase using wooden or plastic scraper, or chemical gasket re- mover.
  • Page 59 CS-271T ENGINE 8-10 Replacing needle bearing NOTE: Always use needle bearing tool 89770511520 to replace needle bearing on small end of connecting rod. 1. Put small end on base (A) of needle bearing tool and fit needle bearing (B) in hole (a) of the base.
  • Page 60 CS-271T ENGINE 8-11 Installing piston and piston ring 1. Set piston pin spacers (A) on small end of con- necting rod (B) as shown. NOTE: Place piston over connecting rod with pis- ton arrow mark (C) pointing as shown. 2. Insert pin guide tool (D) stamped “8”, through piston, with piston pin spacers set at step 1.
  • Page 61 CS-271T ENGINE 8-12 Assembling piston into cylinder 1. Apply 2-stroke oil on cylinder walls, oil seal grooves, piston ring, ball bearing, and both sides of con-rod. 2. Position end gap of piston ring with locating pin (A). 3. Install piston in cylinder with arrow (B) pointing to muffler side.

  • Page 62: Top Handle And Control System

    CS-271T TOP HANDLE AND CONTROL SYSTEM 9 TOP HANDLE AND CONTROL SYSTEM ( A ) Front handle ( B ) Top handle ( C ) Torsion spring ( D ) Throttle trigger ( E ) Throttle rod ( F ) Throttle lockout...
  • Page 63 CS-271T TOP HANDLE AND CONTROL SYSTEM 9-1 Replacing throttle control parts 1. Remove four screws securing top handle lid and a screw securing rubber cushion. 2. Remove top handle lid. 3. Check throttle control parts and replace defec- tive parts with new one as required.

  • Page 64: Guide Bar Mounting System

    CS-271T GUIDE BAR MOUNTING SYSTEM 10 GUIDE BAR MOUNTING SYSTEM ( A ) Sprocket guard ( B ) Sprocket guard plate ( C ) Tensioner screw ( D ) Chain tensioner ( E ) Bevel gear ( F ) Collar...
  • Page 65 CS-271T GUIDE BAR MOUNTING SYSTEM 10-2 Replacing guide bar stud 1. Install two nuts on defective stud and tighten them against each other. 2. Turn nut (A) counterclockwise to remove stud. NOTE: If it is hard to remove or broken stud is too short for tightening two nuts, hold defective stud by vise and turn the chain saw body counterclock- wise, or use a suitable stud remover.

  • Page 66: Maintenance Guide

    CS-271T 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 67 CS-271T MAINTENANCE GUIDE 11-1 Troubleshooting guide (continued) INSPECTING REFERENCES Inspecting first. Fuel system / Carburetor 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Air filter Fuel cap / strainer Carburetor adjustment Fuel tank/line/vent, Purge bulb...
  • Page 68 CS-271T MAINTENANCE GUIDE 11-2 Disassembly chart Sprocket Starter guard assembly (8-1,10-1) Muffler Air cleaner Dust handle lid cover cover cover (9-1) Clutch Air filter Ignition Starter Front Spark plug assembly case switch pawl handle ( 5 ) (3-3) (4-1) (3-6) (2-1)
  • Page 69 CS-271T MAINTENANCE GUIDE 11-3 Service intervals Intervals Inspecting point Service Reference 3 months 6 months Daily or or 100 hours 300 hours Screws and bolts * Retighten / Replace Air filter Clean Inspect / Replace Carburetor Inspect / Repair 4-8 to 4-14 Fuel leaks...

  • Page 70: Index

    CS-271T INDEX Adhesive 4, 59 Fuel line 17, 22, 24, 27, 28, 31, 67 Pulse hole 32 Air filter 15, 22, 23, 27 to 29, 54, 67 Fuel return line 22, 27, 28, 33, 37, 71 Pump diaphragm 31, 34...
  • Page 72 Printed in Japan 1202...

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