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Echo shindaiwa CSG-7410ES Service Manual

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Copyright C 2020 YAMABIKO Corporation All rights reserved.
ECHO:
shindaiwa:
CSG-7410ES
EC741S
(Serial number: 30000001 and after)
(Serial number: 38000001 and after)
REVISED May 2021
Ref. No. 401-45

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Summary of Contents for Echo shindaiwa CSG-7410ES

  • Page 1 CSG-7410ES ECHO: EC741S shindaiwa: (Serial number: 30000001 and after) (Serial number: 38000001 and after) REVISED May 2021 Ref. No. 401-45 Copyright C 2020 YAMABIKO Corporation All rights reserved.
  • Page 2 INTRODUCTION This service manual contains information for ser- vice and maintenance of ECHO ENGINE CUT- OFF SAW, model CSG-7410ES, shindaiwa ENGINE CUT-OFF SAW, model EC741S. 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

    CSG-7410ES EC741S TABLE OF CONTENTS Page Page 1 SERVICE INFORMATION ........2 5 CLUTCH SYSTEM AND BELT DRIVING SYSTEM ...37 Specifications ...........2 Adjusting belt tension ........37 Technical data ..........3 Inspecting and replacing belt......38 Torque limits .............4 Inspecting clutch parts ........40 Special repairing materials .......4 Installing clutch parts ........41 Service Limits ...........5 Special tools .............6...

  • Page 4: Service Information

    CSG-7410ES EC741S SERVICE INFORMATION 1 SERVICE INFORMATION 1-1 Specifications Dimensions* Length mm(in) 620 (24.4) Width mm(in) 240 (9.4) Height mm(in) 407 (16.0) Dry weight* kg(lb) 10.7 (23.6) Engine Type YAMABIKO, air-cooled, two-stroke, single cylinder Rotation Clockwise viewed from the output end Displacement 73.5 (4.485) Bore...

  • Page 5: Technical Data

    CSG-7410ES EC741S SERVICE INFORMATION 1-2 Technical data Engine Compression pressure MPa (kgf/cm ) (psi) 0.99 (10.1) (143) Clutch engagement speed r/min 3,800 Ignition system Spark plug gap mm(in) 0.6 - 0.7 (0.024 - 0.028) Spark test Tester gap w/ spark plug mm(in) 4.0 (0.16) Tester gap w/o spark plug...

  • Page 6: Torque Limits

    CSG-7410ES EC741S SERVICE INFORMATION 1-3 Torque limits Descriptions Size kgf•cm N•m in•lbf Starter system Starter pawl M5** Starter case Ignition system Magneto rotor (Flywheel) M5** Ignition coil Spark plug Fuel system Carburetor, Carburetor elbow M5** Carburetor elbow Clutch Clutch assembly Clutch drum M5** Engine Crankcase...

  • Page 7: Service Limits

    CSG-7410ES EC741S SERVICE INFORMATION 1-5 Service limits 5K253 5K083 5K084 5K081 5K082 5K016 5K025 5K254 5K173 5K174 5K181 5K181 Description mm (in) A Cylinder bore When plating is worn and aluminum can be seen Piston outer diameter Min. 50.89 (2.004) Piston pin bore Max.

  • Page 8: Special Tools

    CSG-7410ES EC741S SERVICE INFORMATION 1-6 Special tools 1, 2, 3 21, 22 23, 24, 25 Part Number Description Reference X602-000350 T-hex. wrench (3 mm) Removing and installing hex. head bolt (M4) X602-000360 T-hex. wrench (4 mm) Removing and installing hex. head bolt (M5) X602-000230 T-hex.

  • Page 9: Starter System

    CSG-7410ES EC741S STARTER SYSTEM 2 STARTER SYSTEM (A) Starter case (G) Power spring (B) Rope guide (H) Shaft (C) Starter grip (J) Cover (D) Rewind spring (K) Oil seal (E) Rope reel (L) Pawl catcher (F) Starter rope (M) Pawl...

  • Page 10: Disassembling Starter Assembly

    CSG-7410ES EC741S STARTER SYSTEM 2-1 Disassembling starter assembly 1. Remove 4 pre-coated bolts and remove starter assembly (A) from unit. 2. Pinch pawl catcher (B) with adjustable wrench (C) as shown not to rotate pawl catcher (B). NOTE: Do not insert rod shaped tool between the pawls of pawl catcher (B) to secure it, otherwise damage of pawl catcher (B) may occur.
  • Page 11 CSG-7410ES EC741S STARTER SYSTEM 2-1 Disassembling starter assembly (Continued) WARNING DANGER Wear eye protection and take care when removing rope reel. Rewind spring may un- wind suddenly and cause personal injury. 9. Remove rope reel (M) from starter case (A) slowly to prevent rewind spring from unwinding. 10. When removing rewind spring (N) from rope reel (M), pinch rewind spring (N) with pliers (P) and lift up as shown.

  • Page 12: Assembling Starter Assembly

    CSG-7410ES EC741S STARTER SYSTEM 2-2 Assembling starter assembly WARNING DANGER Use of eye protection and safety gloves are strongly recommended while working on re- wind spring. 1. If rewind spring (N) is removed from rope reel (M), wind the spring (N) inside rope reel (M) as shown. NOTE: Apply small amount of lithium based grease to surface (m2) of rope reel before winding the spring.
  • Page 13 CSG-7410ES EC741S STARTER SYSTEM 2-2 Assembling starter assembly (Continued) 8. Install power spring (J) to rope reel (M) placing hook (j1) of power spring into groove(m3) of rope reel. 9. Apply small amount of lithium based grease to inside (h1) of shaft (H). lithium 10.

  • Page 14: Replacing Oilseal

    CSG-7410ES EC741S STARTER SYSTEM 2-3 Replacing oilseal 1. Remove cover (G) from starter assembly. (Refer to “2-1 Disassembling starter assembly”) 2. Pry oilseal (Q) from cover (G). 3. Install new oilseal (Q). 2-4 Replacing starter pawl 1. Remove starter assembly from unit. 2. Loosen bolt (A) with 10mm socket wrench and remove pawl (B), spacer (C) spacer (C) and tor- sion spring (D).

  • Page 15: Ignition System

    CSG-7410ES EC741S IGNITION SYSTEM 3 IGNITION SYSTEM (A) Magneto rotor (Flywheel) (E) Spark plug cap (B) Ignition coil (F) Switch lead (C) Spark plug (G) Ignition switch (D) Spark plug cap coil...

  • Page 16: Troubleshooting Guide

    CSG-7410ES EC741S 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. Flywheel Replace flywheel.

  • Page 17: Testing Spark

    CSG-7410ES EC741S IGNITION SYSTEM 3-2 Testing spark WARNING 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. 1. Remove cylinder cover. (Refer to “4-1 Replacing air filter”) 2.

  • Page 18: Replacing Spark Plug Cap And Coil

    CSG-7410ES EC741S IGNITION SYSTEM 3-4 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 (A) away from high tension lead (B).

  • Page 19: Inspecting Ignition Coil And Switch Lead

    CSG-7410ES EC741S IGNITION SYSTEM 3-6 Inspecting ignition coil and switch lead Remove cylinder cover assembly, starter assembly and fan cover. Inspecting ignition coil resistance 1. Connect one probe of Ohm-meter or multimeter to spark plug cap coil. 2. Connect the other probe to ignition coil core to measure secondary coil resistance.

  • Page 20: Replacing Ignition Coil

    CSG-7410ES EC741S IGNITION SYSTEM 3-7 Replacing ignition coil 1. Remove cylinder cover assembly, filter case, cover stay (Refer to “4-1 Replacing air filter” and “4-5 Removing carburetor, fuel line and tank vent”). 2. Remove starter assembly and fan cover (Refer to “2-1 Disassembling starter assembly“). 3.

  • Page 21: Inspecting And Replacing Magneto Rotor And Key

    CSG-7410ES EC741S IGNITION SYSTEM 3-9 Inspecting and replacing magneto rotor and key 1. Inspect magnetic force of magneto rotor using flux meter, or bridging with flat head screwdriver (A) as shown. 2. If magnetic force is weak, replace flywheel as follows. 3. Install piston stopper X644-000020 (C) or clean rope into spark plug hole by hand, to stop crank- shaft rotation.
  • Page 22 CSG-7410ES EC741S IGNITION SYSTEM 3-9 Inspecting and replacing magneto rotor and key (continued) 7. Inspect woodruff key for damage or shearing. Replace as required. 8. Wipe off oil from taper part of crankshaft before assembling magneto rotor. 9. Install woodruff key into key groove as shown. 10.

  • Page 23: Fuel System

    CSG-7410ES EC741S FUEL SYSTEM 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 ) Pressure line ( J ) Carburetor ( K ) Carburetor elbow...

  • Page 24: Replacing Air Filter

    CSG-7410ES EC741S FUEL SYSTEM 4-1 Replacing air filter IMPORTANT: Air filters on CSG-7410ES and EC741S are designed to be maintenancefree for a long pe- riod of time. However, in the following cases the main and sub air filters should be replaced. - When engine output drops remarkably - After 1 year or 50 hours of operation NOTE: Do not clean the main or sub air filters with compressed air.

  • Page 25: Inspecting Fuel Cap And Fuel Strainer

    CSG-7410ES EC741S FUEL SYSTEM 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 a new one as required. 3. Replace fuel cap (B) if damaged. 4. Pull fuel strainer (C) from fuel tank using a wire hook (D).

  • Page 26: Inspecting Fuel Tank And Line

    CSG-7410ES EC741S FUEL SYSTEM 4-3 Inspecting fuel tank and fuel line 1. Clean fuel tank inside as required. 2. Remove cylinder cover and filter case (Refer to “4-1 Replacing air filter”). 3. Disconnect fuel line (A) from carburetor. 4. Connect Pressure tester 897803-30133 (B) to fuel line (A).

  • Page 27: Testing Carburetor

    CSG-7410ES EC741S FUEL SYSTEM 4-4 Testing carburetor NOTE: To perform this test, carburetor interior should be wet with fuel. If dry, a little leakage may occur from diaphragms and/or inlet needle seat. 1. Remove cylinder cover assembly and filter case (Refer to “4-1 Replacing air filter”). 2.

  • Page 28: Removing Carburetor, Fuel Line And Tank Vent

    CSG-7410ES EC741S FUEL SYSTEM 4-5 Removing carburetor, fuel line and tank vent 1. Remove cylinder cover assembly and filter case (Refer to “4-1 Replacing air filter”). 2. Remove 3 pre-coarted bolts (A) and cover stay (B) 3. Remove 2 bolts (C) and bolt (D) from carburetor elbow.

  • Page 29: Inspecting Tank Vent

    CSG-7410ES EC741S FUEL SYSTEM 4-6 Inspecting 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. Inspection using Pressure / vacuum tester 91149 1.

  • Page 30: Replacing Purge Bulb

    CSG-7410ES EC741S FUEL SYSTEM 4-7 Replacing purge bulb 1. Remove carburetor from unit (Refer to “4-5 Re- moving carburetor, fuel line and tank vent”). 2. Disconnect fuel return line (B) and purge line (C) from purge bulb (A). 3. Press leg of purge bulb (A) with appropriated tool and remove the purge bulb.

  • Page 31: Inspecting Metering Chamber And Inlet Needle Valve

    CSG-7410ES EC741S FUEL SYSTEM 4-9 Inspecting metering chamber and inlet needle valve 1. Remove 4 screws (A), metering diaphragm cov- er (B), metering diaphragm (C) and gasket (D). 2. Inspect metering diaphragm (C) for hardening, distortion or pin hole. Replace as required. 3. Inspect metering gasket (D) and replace if de- fective.

  • Page 32: Inspecting Metering Lever Height

    CSG-7410ES EC741S FUEL SYSTEM 4-9 Inspecting metering chamber and inlet needle valve (Continued) 6. Inspect inlet needle valve (J) if worn or sticky. Clean or replace as required. 7. Clean inlet needle valve seat (K) using suitable clean solvent (do not use metal tools). NOTE: Causes of fuel flooding from carburetor to cylinder are as follows: - Improper assembling of metering lever (F) and...

  • Page 33: Inspecting Pump Diaphragm And Inlet Screen

    CSG-7410ES EC741S FUEL SYSTEM 4-11 Inspecting pump diaphragm and inlet screen 1. Remove screw (A), pump cover (B), pump gas- ket (C), pump diaphragm (D) and (E). 2. Inspect pump diaphragm (D) and (E). Replace if hardened or curled at valve tabs. 3. Inspect pump gasket (C). Replace if defective. 4.

  • Page 34: Installing Carburetor, Fuel Line And Tank Vent

    CSG-7410ES EC741S FUEL SYSTEM 4-13 Installing carburetor, fuel line and tank vent 1. Install fuel line (A), pipe joint (B), fuel return line (C), grommet (D), pipe joint (E), clip (F) and vent line (G) to rear handle as shown. NOTE: Make sure to pass fuel line (A) through groove of rear handle as shown.
  • Page 35 CSG-7410ES EC741S FUEL SYSTEM 4-13 Installing carburetor, fuel line and tank vent (Continued) 7. Connect fuel return line (M) to fuel outlet (k2) on carburetor. 8. Connect choke rod (N) to choke lever (k3) on carburetor as shown. 9. Connect throttle rod (P) to throttle lever (k4) on carburetor as shown.
  • Page 36 CSG-7410ES EC741S FUEL SYSTEM 4-13 Installing carburetor, fuel line and tank vent (Continued) 12. Connect pressure line (L) to joint of carburetor elbow (R). 13. Place intake gasket (S) on carburetor elbow (R) as shown. 14. Secure carburetor elbow (R), intake gasket (S) and carburetor (K) with 2 bolts (T), 2 spring wash- ers (U), 2 washers (V) and pre-coated bolt (W) as shown.

  • Page 37: Adjusting Carburetor

    CSG-7410ES EC741S FUEL SYSTEM 4-14 Adjusting carburetor 4-14-1 General adjusting rules A. Before adjustment, check the following items. 1. The correct spark plug must be clean and properly gapped. 2. The air filters must be clean and properly installed. 3. The muffler exhaust port must be clear of carbon. 4.

  • Page 38: Adjusting Carburetor

    CSG-7410ES EC741S FUEL SYSTEM 4-14-3 Adjusting carburetor 1. Remove cutter blade from unit. NOTE: Cutter blade can affect setting of idle maxi- mum speed. 2. Start and run engine for 120 seconds alternat- ing engine speed between WOT 5 seconds and idle 10 seconds.

  • Page 39: Clutch System And Belt Driving System

    CSG-7410ES EC741S CLUTCH SYSTEM and BELT DRIVING SYSTEM 5 CLUTCH SYSTEM AND BELT DRIVING SYSTEM ( A ) Clutch cover ( B ) Clutch drum ( C ) Clutch hub ( D ) Clutch spring ( E ) Clutch shoe ( F ) Clutch boss ( E ) Belt 5-1 Adjusting belt tension...

  • Page 40: Inspecting And Replacing Belt

    CSG-7410ES EC741S CLUTCH SYSTEM and BELT DRIVING SYSTEM 5-2 Inspecting and replacing belt 1. Disconnect pipe (F) from pipe connector on cut- ter cover assembly. 2. Turn bolt (C) counterclockwise to loosen belt tension and then remove 2 bolts (B) and pulley cover (A). 3.
  • Page 41 CSG-7410ES EC741S CLUTCH SYSTEM and BELT DRIVING SYSTEM 5-2 Inspecting and replacing belt (Continued) 8. Install clutch cover (N) while pulling belt (Q) for- ward as shown. 9. Tighten 2 pre-coated bolts (P). NOTE: If the coat is peeled off, replace new one or apply ThreeBond #1344 or equivalent.

  • Page 42: Inspecting Clutch Parts

    CSG-7410ES EC741S CLUTCH SYSTEM and BELT DRIVING SYSTEM 5-3 Inspecting clutch parts 1. Remove pulley cover, clutch cover and cutter cover assembly (Refer to “5-2 Inspecting and re- placing belt). 2. Remove cylinder cover assembly (Refer to “4-1 Replacing air filter). 3. If starter assembly is installed, remove spark plug and then pull starter rope out, and make a temporary knot (B) to prevent starter damage when installing clutch assembly.

  • Page 43: Installing Clutch Parts

    CSG-7410ES EC741S CLUTCH SYSTEM and BELT DRIVING SYSTEM 5-4 Installing clutch parts 1. Install clutch assembly (F; Left-hand thread) to crankshaft turning counterclockwise by hand until it can not be 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”).

  • Page 44: Handle And Control System

    CSG-7410ES EC741S HANDLE AND CONTROL SYSTEM 6 HANDLE AND CONTROL SYSTEM ( A ) Front handle ( B ) Rear handle ( C ) Torsion spring ( D ) Throttle trigger ( E ) Throttle lockout ( F ) Rear handle cover ( G ) Cushion (5pcs.) ( H ) Cushion ( J ) Cushion...

  • Page 45: Replacing Cushions And Rear Handle

    CSG-7410ES EC741S HANDLE AND CONTROL SYSTEM 6-1 Replacing cushions and rear handle 1. Remove starter assembly, carburetor, cutter cover assembly, front handle and throttle system referring to the following section. Starter assembly; “2-1 Disassembling starter as- sembly” Carburetor; “4-5 Removing carburetor, fuel line and tank vent”...

  • Page 46: Replacing Throttle System

    CSG-7410ES EC741S HANDLE AND CONTROL SYSTEM 6-2 Replacing throttle system 1. Remove bolt (A) and rear handle cover (B). 2. Remove throttle lever (C), throttle lockout (D) torsion spring (E) from rear handle. Remove car- buretor before removing throttle rod (F) (Refer to “4-5 Removing carburetor, fuel line and tank vent”).

  • Page 47: Engine

    CSG-7410ES EC741S ENGINE 7 ENGINE ( A ) Crankshaft assembly ( Q ) Band ( B ) Ball bearing (2 pcs.) ( R ) Intake bellows ( C ) Oil seal (2 pcs.) ( S ) Seal ( D ) Crankcase ( T ) Intake insulator ( E ) Needle bearing ( U ) Muffler gasket...

  • Page 48: Cleaning Cooling Air Passages

    CSG-7410ES EC741S ENGINE 7-1 Cleaning cooling air passages 1. Inspect cylinder cooling fins (A) for blockage with dirt. Clean them with wooden or plastic stick or compressed air. WARNING DANGER Always wear eye protection when using compressed air for cleaning. Otherwise, eye damage can occur from flying particles. 2.

  • Page 49: Testing Cylinder Compression

    CSG-7410ES EC741S ENGINE 7-2 Inspecting muffl er and exhaust port (Continued) 6. Remove exhaust guide (C) and spark arrestor screen (D) from muffl er. 7. Remove carbon deposits from spark arrestor screen (D) and exhaust guide (C). If the screen and the guide have heavy deposits, replace with new one(s).

  • Page 50: Testing Crankcase And Cylinder Seal

    CSG-7410ES EC741S ENGINE 7-4 Testing crankcase and cylinder seal 1. Remove muffler. 2. Set Pressure rubber plug 91041 (D) on muffler to cover exhaust port as shown. 3. Reinstall muffler with Pressure rubber plug 91041 (D) on cylinder to seal exhaust port. Secure them with 4 muffler bolts. 3.

  • Page 51: Inspecting Decompressor

    CSG-7410ES EC741S ENGINE 7-5 Inspecting decompressor NOTE: When the area around decompressor (A) is extremely dirty, leakage of exhaust gas can be oc- cured due to carbon deposits around valve (a1) of decompressor (A). Inspect as follows. 1. Remove decompressor (A) from cylinder with 13mm socket wrench.

  • Page 52: Inspecting Cylinder And Intake Parts

    CSG-7410ES EC741S ENGINE 7-6 Inspecting cylinder and intake parts Removing cylinder 1. Remove starter assembly, carburetor, cutter cover assembly and muffler referring to the follow- ing section. Starter assembly; “2-1 Disassembling starter as- sembly” Carburetor; “4-5 Removing carburetor, fuel line and tank vent” Cutter cover assembly; “ 5-2 Inspecting and replac- ing belt”...

  • Page 53: Inspecting Piston And Piston Ring

    CSG-7410ES EC741S ENGINE 7-7 Inspecting piston and piston ring 1. Inspect piston ring (A) and (B). If broken or scored, or if it exceeds service limits (Refer to “1-5”), replace with new one(s) (Refer to “7-10 I n s t a l l i n g piston and cylinder”).

  • Page 54: Disassembling Crankcase

    CSG-7410ES EC741S ENGINE 7-8 Disassembling crankcase Separating crankcase 1. Referring to “9-1 Disassembly chart”, remove necessary parts for crankcase disassembly. 2. Remove woodruff key from crankshaft magneto rotor end. 3. Remove 6 bolts from crankcase. 4. Screw long 4 bolts (length: approx. 75 - 80 mm) on one side of crankcase halves (in the picture, magneto side is shown).

  • Page 55: Assembling Crankcase

    CSG-7410ES EC741S ENGINE 7-9 Assembling crankcase Preparation for assembling 1. Apply lithium based grease on inner rubber lips of new oil seal. 2. Lubricate circumferences of ball bearing with 2 stroke oil. Inserting ball bearing and oil seal NOTE: There are 2 ways to insert ball bearing and oil seal as follows, depending on service tools.
  • Page 56 CSG-7410ES EC741S ENGINE 7-9 Assembling crankcase (Continued) 2) Using Holder 22169-96410, X643-000020, Rod oil seal 22182-96460, X646-000060, Rod bearing X646-000050 and X646-000081 Flywheel side Clutch side Holder; 22169-96410 Holder; X643-000020 d1= 10mm d3 = 10mm d2= 58mm d4 = 46mm L = 75mm Rod oil seal;...
  • Page 57 CSG-7410ES EC741S ENGINE 7-9 Assembling crankcase (Continued) Assembling crankshaft and crankcase 1. Clean mating surface of each crankcase half. 2. Heat ball bearing for easier installation. WARNING DANGER When using a heat gun, wear gloves. Other- wise, a burn will result. 3. Put new crankcase gasket (Q) on clutch side crankcase half. 4.
  • Page 58 CSG-7410ES EC741S ENGINE 7-9 Assembling crankcase (Continued) 8. Tap both ends of crankshaft with plastic mallet several times for crankshaft smooth rotation. 9. Tighten 6 bolts to to secure crankcase halves to- gether and recheck crankshaft for smooth rotation. NOTE: If crankshaft does not rotate smoothly, loose 6 bolts and tap both ends of crankshaft with plastic mallet several times.

  • Page 59: Installing Piston And Cylinder

    CSG-7410ES EC741S ENGINE 7-10 Installing piston and cylinder Installing piston and piston rings 1. Lubricate needle bearing with 2-stroke oil and then insert the needle bearing into small end of connecting rod. 2. Place piston over the small end of connecting rod, so that the arrow mark (A) on piston points front (muffler side) as shown.
  • Page 60 CSG-7410ES EC741S ENGINE 7-10 Installing piston and cylinder (Continued) Installing intake parts and cylinder 1. Insert intake pipe (K) into intake port of cylinder. 2. Place band (J) on intake bellows (H) as shown. 3. Place intake bellows (H) with band (J) on intake port of cylinder to align mark (d3) on cylinder and mark (h1) on intake bellows.

  • Page 61: Cutting System

    CSG-7410ES EC741S CUTTING SYSTEM 8 CUTTING SYSTEM ( A ) Pulley cover ( B ) Pulley ( C ) Bearing case ( D ) Drive shaft ( E ) Locking knob ( F ) Cutter cover ( G) Cutter cover knob ( H ) Inner frange ( J ) Collar ( K ) Snap ring...

  • Page 62: Disassembling Cutter Cover Assembly

    CSG-7410ES EC741S CUTTING SYSTEM 8-1 Disassembling cutter cover assembly 1. Loosen tension screw (A). 2. Remove 2 bolts (C) with 13mm socket wrench and slide pulley cover (B) forward to remove it. 3. Remove cutter cover assembly from unit. 4. Remove bolt (D) with 19 mm socket wrench and then remove outer frange (E).

  • Page 63: Replacing Pulley, Drive Shaft And Ball Bearing

    CSG-7410ES EC741S CUTTING SYSTEM 8-1 Disassembling cutter cover assembly (Continued) 10. Remove cutter cover knob (S). 11. Disconnect pipe (M) from pipe connector on cutter cover assembly. 12. Remove 2 cushions (T) from cutter cover as- sembly. 13. Remove ring (U) from cutter cover assembly. 8-2 Replacing pulley, drive shaft and ball bearing Removing pulley, drive shaft and ball bearing 1.
  • Page 64 CSG-7410ES EC741S CUTTING SYSTEM 8-2 Replacing pulley, drive shaft and ball bearing 5. Remove sliding ring (J) from bearing case (A). 6. Heat bearing case (A) to remove ball bearing easier. WARNING DANGER When using a heat gun, wear gloves. Other- wise, a burn will result. 7. Push drive shaft (K) to remove drive shaft (K) with ball bearing from bearing case. Installing drive shaft, ball bearing and pulley 1.

  • Page 65: Assembling Cutter Cover Assembly

    CSG-7410ES EC741S CUTTING SYSTEM 8-3 Assembling cutter cover assembly 1. Set slide plate (A) on plate (B) as shown. 2. Tighten bearing case (C) and plate (B) with 2 pre-coated bolts (D). NOTE: If the coat is peeled off, replace new one or apply ThreeBond #1344 or equivalent.
  • Page 66 CSG-7410ES EC741S CUTTING SYSTEM 8-3 Assembling cutter cover assembly (Continued) 8. Install 2 cushions (L) on cutter cover. 9. Connect water flush pipe (M) to pipe connector. 10. Pass water flush pipe (M) over nut (N) on cut- ter cover as shown. 11.

  • Page 67: Maintenance Guide

    CSG-7410ES EC741S MAINTENANCE GUIDE 9 MAINTENANCE GUIDE 9-1 Disassembly chart...

  • Page 68: Troubleshooting Guide

    CSG-7410ES EC741S MAINTENANCE GUIDE 9-2 Troubleshooting guide TROUBLE Engine does not crank. Engine does not start. Poor / No spark Spark plug is not wet. Idling is not stable. Acceleration is poor. Engine lacks power. Engine stops while running. Engine seizure / overheat Engine does not stop.
  • Page 69 CSG-7410ES EC741S MAINTENANCE GUIDE 9-2 Troubleshooting guide (Continued) INSPECTING REFERENCES Inspecting first. Fuel system / Carburetor 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Air filter Fuel cap / strainer Carburetor adjustment 4-14 Fuel tank / line / vent 4-3, 4-5, 4-6 Grommets 4-5, 4-13...

  • Page 70: Service Intervals

    CSG-7410ES EC741S MAINTENANCE GUIDE 9-3 Service Intervals Intervals Inspection point Reference 50 hours Before use 100 hours or 1year Cutter blade Belt 5-1, 5-2 Cutter cover 8-1, 8-2 Flange Air filter Fuel Fuel leaks** 4-3, 4-5, 4-13 Fuel strainer Fuel line / Grommet 4-3, 4-5, 4-13 Fuel tank cap / O-ring Fuel tank Spark plug 3-2, 3-3...
  • Page 71 CSG-7410ES EC741S MEMORANDUM...
  • Page 72 CSG-7410ES EC741S MEMORANDUM...
  • Page 73 CSG-7410ES EC741S MEMORANDUM...
  • Page 74 Published by YAMABIKO Corp. Tokyo Japan 2005...

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