Page 2
INTRODUCTION This service manual contains information for service and maintenance of ECHO CHAIN SAW, model CS-370ES, CS-420ES. 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.
CS-370ES TABLE OF CONTENTS CS-420ES Page Page 1 SERVICE INFORMATION ........2 5 CLUTCH SYSTEM ..........35 Specifications ..........2 Inspecting clutch parts ........35 Technical data ..........3 Replacing clutch parts ........36 Installing clutch assembly ......36 Torque limits ............ 4 Special repairing materials ......
CS-370ES SERVICE INFORMATION CS-420ES 1-1 Specifications (continued) Cutting devices CS-420ES Guide bar Part No. 38RD58-325 43RD58-325 Called length Gauge 0.058 Saw chain Type CARLTON K2L OREGON 21BP Number of drive links Pitch 0.325 Gauge 0.058 1-2 Technical data Model CS-370ES...
CS-370ES SERVICE INFORMATION CS-420ES 1-5 Service Limits 5K275 5K277 5K278 5K279 5K280 5K016 5K042 5K276 5K173 5K174 5K190 5K191 Description mm (in) CS-370ES CS-420ES A Cylinder bore When plating is worn and aluminum can be seen B Piston outer diameter Min.
CS-370ES SERVICE INFORMATION CS-420ES 1-6 Special tools a = 3 mm a = 4 mm Part Number Description Reference 990511-30017 Tachometer PET-1000 Measuring engine speed 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolts (M4) 895610-79920 L-hex wrench (4 mm) Removing and installing hex.
CS-370ES CS-420ES STARTER SYSTEM 2 STARTER SYSTEM (ES starter) (A) Starter case (B) Rewind spring (C) Rewind spring case assembly (D) Rope reel (E) Power Spring (e) Hook end of power spring (F) Pawl catcher Construction Working principle 1. Rewind spring case assembly (C) is installed 1.
CS-370ES STARTER SYSTEM CS-420ES 2-1 Disassembling starter assembly 1. Remove four bolts securing recoil starter assembly. Remove recoil starter assembly from unit. 2. Pull out starter rope about 30 centimeters (12 in) and hold rope reel (A). Loop excess rope in rope reel notch (B) as shown.
CS-370ES CS-420ES STARTER SYSTEM 2-2 Replacing starter rope 1. Pull out and untie knot (A). 2. Pull out knot (C) from rope reel (B). 3. When installing a new starter rope, singe both ends of the rope to prevent fraying.
CS-370ES STARTER SYSTEM CS-420ES 2-3 Assembling starter 1. If rewind spring (B) is unwound from rewind spring case (A), wind the spring inside case as shown. 2. Install rewind spring case assembly on starter case matching hole (C) with post (D). Hook (E) of rewind spring should contact with post of starter case.
Page 13
CS-370ES CS-420ES STARTER SYSTEM 2-3 Assembling starter (continued) 4. Check for proper engagement of rewind spring and rope reel by turning rope reel (F) clockwise and counterclockwise. 5. Install power spring assembling hook (G) of power spring into rope reel cutout (H).
CS-370ES STARTER SYSTEM CS-420ES 2-3 Assembling starter (continued) 7. Fasten screw (P) on starter post. 8. Pull out starter rope inside starter case. Rotate rope reel clockwise several turns with starter rope hooked at notch (Q) as shown. Hold rope reel to prevent it from rewinding and pull out starter grip to take the rope slack.
Page 15
CS-370ES CS-420ES STARTER SYSTEM 2-4 Replacing starter pawl (continued) 3. Install torsion spring, spacer, pawl, washer and bolt. To avoid pinching of torsion spring, install these parts without setting the hook (E) of torsion spring on starter pawl. The bolt is pre-coated with sealant on the thread.
CS-370ES CS-420ES 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.) Spark plug Regap / S.T. Replace.
CS-370ES CS-420ES IGNITION SYSTEM 3-2 Testing spark 1. Remove air cleaner cover and remove spark plug cap from spark plug. 2. Connect spark tester 990511-30023 (A) to high tension lead and connect tester lead (B) on spark plug. 3. Screw in adjuster (C) until the needle tips contact.
CS-370ES CS-420ES IGNITION SYSTEM 3-4 Inspecting ignition switch 1. Remove cylinder cover. 2. Connect one probe of Ohm-meter or multi-meter to primary lead (A) and the other probe to cylinder fin. 3. When ignition switch is in “RUN” position, tester should indicate infinite resistance.
CS-370ES CS-420ES IGNITION SYSTEM 3-6 Inspecting ignition coil resistance 1. Remove cylinder cover. 2. Connect one probe of Ohm-meter or multimeter (Power source DC 1.5V) to spark plug cap coil (A). 3. Connect the other probe to cylinder (B) to measure secondary coil resistance.
CS-370ES CS-420ES IGNITION SYSTEM 3-8 Replacing ignition coil 1. Disconnect spark plug cap from spark plug and remove starter assembly and cylinder cover. 2. Disconnect primary lead (A) and ground lead (B) from ignition coil. Loosen bolts (C) of ignition coil.
CS-370ES CS-420ES IGNITION SYSTEM 3-10 Inspecting flywheel and key 1. Inspect magnetic force of flywheel using flux meter, or bridging with a screwdriver. 2. If magnetic force is weak, replace flywheel as follows. 3. Install piston stopper 897537-30130 (A) into spark plug hole by hand, to stop crankshaft rotation.
CS-370ES CS-420ES FUEL SYSTEM 4-1 Inspecting air filter 1. Close choke shutter. Remove cleaner lid, air cleaner bracket and air filter. DANGER Wear eye protection when working with com- pressed air. Eye damage can occur from flying particles. 2. Inspect the surface of air filter. If blocked with dirt or dust, remove the obstruction using brush.
CS-370ES CS-420ES FUEL SYSTEM 4-3 Replacing purge bulb NOTE: It is possible to replace purge bulb, without removing carburetor from the unit. 1. Remove switch bracket (A) from engine cover (Refer to “3-5 Replacing ignition switch”). 2. Remove fuel return line (B) and fuel inlet line (C) from purge bulb.
CS-370ES CS-420ES FUEL SYSTEM 4-4 Inspecting fuel tank and line 1. Clean fuel tank inside as required. 2. Remove cylinder cover, disconnect fuel line (A) from carburetor. 3. Connect pressure tester 897803-30133 (B) to fuel line. NOTE: To connect pressure tester to fuel line easily, it is recommended to use pipe joint V186-000020 (C).
CS-370ES CS-420ES FUEL SYSTEM 4-5 Inspecting and replacing tank vent NOTE: Tank vent prevents a vacuum from forming in fuel tank when fuel in fuel tank is being consumed. When pressure in fuel tank becomes too high, tank vent releases the pressure.
CS-370ES CS-420ES FUEL SYSTEM 4-6 Replacing fuel line, fuel tank vent assembly and grommet 1. Remove engine cover and engine block from rear handle (Refer to “9-2 Inspecting cushions”). 2. Inspect fuel line (A), fuel tank vent assembly (B), fuel return line (C) and fuel tank. Replace them if defective.
CS-370ES CS-420ES FUEL SYSTEM 4-7 Adjusting carburetor 4-7-1 General adjusting rules A. Before starting the unit for adjustment, check the following items. 1. The correct spark plug must be clean and properly gapped. 2. The air filter element must be clean and properly installed.
Page 30
5. Turn L and H mixture needles clockwise until lightly seated, and then turn out both mixture needles following turns. CS-370ES: L mix. needle1 1/4, H mix. needle 2 3/8 CS-420ES: L mix. needle1 3/8, H mix. needle 2 3/4 NOTE: If needles are overtighten during seating, damage to carburetor may occur.
3. Adjust L mixture needle to reach maximum engine rpm just before lean drop off. 4. Set idle engine speed to 3,800 rpm (CS-370ES, CS-420ES) by turning idle adjust screw. Engine rpm should be stable at 3,800 +/- 10 rpm after idle adjust screw adjustment.
When it is cold weather lower than 10 ºC and acceleration is poor, change place of the plug on air cleaner cover from closed position (normal) to opened position. 1. Air cleaner cover on CS-370ES and CS-420ES has plug. 2. The picture shows normal position of the plug (A).
CS-370ES CS-420ES FUEL SYSTEM 4-9 Testing carburetor NOTE: To perform this test, fuel should be inside carburetor. If not, a little leakage may occur from dry diaphragm and/or inlet needle seat. 1. Remove cylinder cover and disconnect fuel line from carburetor. Connect pressure tester 897803- 30133 (A) to carburetor fuel inlet.
CS-370ES CS-420ES FUEL SYSTEM 4-11 Inspecting metering lever height 1. Remove carburetor. 2. Remove metering diaphragm cover, metering diaphragm and gasket. 3. Inspect metering lever height by Metering lever gauge 897563-19830 (A). Metering lever height: 1.65 mm (0.068 in) lower than diaphragm seat (B) 4.
CS-370ES CS-420ES FUEL SYSTEM 4-13 Replacing Welch plug If engine does not run smoothly even after readjusting carburetor and inspecting carburetor parts, inspect low speed ports on carburetor as follows: 1. Remove metering lever and related parts to protect them from damage.
CS-370ES CS-420ES FUEL SYSTEM 4-15 Installing carburetor 1. Connect pulse line (A) and fuel line (B) to fittings on carburetor. 2. Place carburetor elbow on carburetor and pass two screws through the holes (C). 3. Install carburetor and carburetor elbow (D) with three screws (E), passing fuel inlet line (F) under fuel line (B) and fuel return line (G) as shown.
CS-370ES CS-420ES CLUTCH SYSTEM 5-2 Replacing clutch parts 1. Install tension spring (C) to clutch shoes (B). 2. Set one arm of clutch hub (A) to one clutch shoe. 3. Install other two clutch shoes on two arms as shown.
CS-370ES CS-420ES SAW CHAIN LUBRICATION SYSTEM 6-4 Replacing oil line and grommet 1. Remove clutch assembly referring to “5-1 Inspecting clutch parts”. 2. Remove clutch plate, clutch drum, needle bearing and washer. 3. Pull out oil strainer from oil tank (Refer to “6-1 Inspecting oil cap and strainer”) and remove oil...
CS-370ES CS-420ES SAW CHAIN LUBRICATION SYSTEM 6-5 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 897501-03938 into the hole of plug (A), and connect PTO shaft puller 897603-23030 (C) as shown.
CS-370ES CS-420ES SAW CHAIN LUBRICATION SYSTEM 6-6 Replacing V-ring 1. Inspect V-ring on plunger for hardness or damage. Replace as follows if required. 2. Secure V-ring (A) and insert thin steel wire such as paper clip through the opening as shown.
CS-370ES CS-420ES SAW CHAIN LUBRICATION SYSTEM 6-7 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.
CS-370ES CS-420ES ENGINE 7-1 Testing cylinder compression NOTE: Test cylinder compression when engine is cold. 1. Move ignition switch to STOP position. Then remove 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.
CS-370ES CS-420ES ENGINE 7-3 Inspecting muffler and exhaust port 1. Remove cylinder cover and muffler. 2. Inspect cylinder exhaust port and clean the port using wooden or plastic stick if carbon is found. NOTE: When cleaning exhaust port, always position piston at Top Dead Center (TDC) to prevent carbon from entering cylinder.
CS-370ES CS-420ES ENGINE 7-6 Inspecting cylinder 1. Remove muffler (A) and muffler gasket from cylinder. 2. Disconnect intake insulator (B) from intake bellows (C) and pulse line (D) taking care not to damage them. 3. Remove intake bellows (C) and pulse line (D) from cylinder.
CS-370ES CS-420ES ENGINE 7-8 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 remover.
CS-370ES CS-420ES ENGINE 7-10 Installing piston and piston ring 1. Lubricate needle bearing with 2-stroke engine oil. 2. Set needle bearing and piston pin spacers (A) on small end of connecting rod (B) as shown. NOTE: Place piston pin spacers on connecting rod with dents (a) inside as shown.
CS-370ES CS-420ES ENGINE 7-11 Installing 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.
CS-370ES CS-420ES ENGINE 7-12 Installing engine block 1. Assemble muffler gasket and muffler (A) to cylinder. 2. Assemble gasket (B), intake bellows (C) and pulse line (D) to cylinder. 3. Pass pulse line (D) through hole (E) of intake insulator. Install the flange (F) of intake bellows in hole (G) of intake insulator.
CS-370ES CS-420ES CHAIN BRAKE SYSTEM 8-2 Assembling brake parts 1. Assemble brake band (A) together with spacer (B), brake connector (C) and collar (D), placing the notch (b) of spacer as shown. Install roller (E) through brake band hole (F).
CS-370ES CS-420ES REAR HANDLE AND CONTROL SYSTEM 9 REAR HANDLE AND CONTROL SYSTEM (A) Rear handle (B) Torsion spring (C) Spring pin (D) Throttle trigger (E) Throttle lockout (F) Rear handle cover (G) Throttle latch (CS-370) (H) Cushion (I) Collar...
CS-370ES CS-420ES REAR HANDLE AND CONTROL SYSTEM 9-1 Replacing throttle latch (CS-370) 1. Remove throttle latch (A) from rear handle with 13 mm wrench. WARNING Always wear eye protection when using com- pressed air for cleaning. Otherwise, eye damage can occur from flying particles 2.
Page 58
CS-370ES CS-420ES REAR HANDLE AND CONTROL SYSTEM 9-2 Replacing cushions (continued) 7. To remove cushion (B) and (C), push out cushion as shown. 8. Apply lithium-based grease on outer surfaces (b), then push in cushion as shown. 9. Remove cushion (D) with needlenose pliers, cutting off glued part (d) with cutter.
CS-370ES CS-420ES REAR HANDLE AND CONTROL SYSTEM 9-2 Replacing cushions (continued) 12. Put rear handle on the unit. 13. Tighten cushion bolts. Apply approximately 0.5 g (0.001 lb) lithium-based grease (E) inside cushion. 14. Install cushion caps to cushions using needlenose pliers.
Page 60
CS-370ES CS-420ES REAR HANDLE AND CONTROL SYSTEM 9-3 Replacing throttle trigger (continued) 6. Install throttle trigger (A) with torsion spring (B) and insert spring pin (C) as follows. 1) Insert spring pin (C) in the hole of rear handle so the tip of spring pin does not protrude inside handle.
CS-370ES CS-420ES GUIDE BAR MOUNTING SYSTEM 10-3 Installing guide bar stud 1. Apply adhesive (Loctite #675, 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).
CS-370ES MAINTENANCE GUIDE CS-420ES 11-2 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 overheats. Engine misfires. Engine / others are extremely noisy.
Need help?
Do you have a question about the CS-370ES and is the answer not in the manual?
Questions and answers
My card was denied I got no other card.