Echo CS-350WES Service Manual
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Echo CS-350WES Service Manual

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Ord. No. 401-24

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  • Page 1 Ord. No. 401-24...
  • Page 2 INTRODUCTION This service manual contains information for service and maintenance of ECHO CHAIN SAW; model CS-350WES. For systematic diagnosis, to avoid extra work and time loss, please refer to "Troubleshooting guide" that describes problems, tests, remedies and references. We recommend you...

  • Page 3: Table Of Contents

    CS-350WES TABLE OF CONTENTS Page Page 1 SERVICE INFORMATION ........2 Replacing clutch parts ........39 Specifications ..........2 Installing clutch assembly ......39 Technical data ..........3 Torque limits ............ 4 6 SAW CHAIN LUBRICATION SYSTEM ..... 40 Special repairing materials ......4 Checking oil cap and strainer .......

  • Page 4: Service Information

    SERVICE INFORMATION CS-350WES 1 SERVICE INFORMATION 1-1 Specifications Model CS-350WES Dimensions Length* mm(in) 392 (15.4) Width mm(in) 241 (9.5) Height mm(in) 236 (9.3) Dry weight* kg(lb) 3.6 (7.9) Engine Type KIORITZ, air-cooled, two-stroke, single cylinder Rotation Clockwise as viewed from the output end Displacement 35.8 (2.185)

  • Page 5: Technical Data

    CS-350WES SERVICE INFORMATION 1-2 Technical data Model CS-350WES Engine Idling speed r/min 2900 - 3500 Operating speed* r/min 9300 - 10200 High speed (No load full throttle)* r/min 12500 - 13500 Clutch engagement speed* r/min 4000 - 4450 Compression pressure...

  • Page 6: Torque Limits

    SERVICE INFORMATION CS-350WES 1-3 Torque limits Descriptions Size kgf•cm N•m in•lbf Starter Starter pawl M 5* 40 - 60 4 - 6 35 - 50 system Starter case M 4** 10 - 20 1 - 2 9 - 18 Ignition Magneto rotor (Flywheel)

  • Page 7: Service Limits

    CS-350WES SERVICE INFORMATION 1-5 Service Limits 5K256 5K257 5K258 5K259 5K260 5K016 5K042 5K261 5K173 5K174 5K190 5K191 mm (in) A Cylinder bore When plating is worn and aluminium can be seen B Piston outer diameter Min. 38.91 (1.532) C Piston pin bore Max.

  • Page 8: Special Tools

    SERVICE INFORMATION CS-350WES 1-6 Special tools a = 3 mm a = 4 mm Part Number Description Used for: 897801-33330 Tachometer PET-1000 Measuring engine speed to adjust carburetor 895612-79920 L-hex wrench (3 mm) Removing and installing hex. socket bolt (M4)

  • Page 9: Starter System (Effortless Starter)

    STARTER SYSTEM CS-350WES 2 STARTER SYSTEM (Effortless starter) ( A ) Starter case ( B ) Rewind spring ( C ) Rewind spring case assembly ( D ) Rope reel ( E ) Power Spring ( e ) Hook end of power spring...

  • Page 10: Disassembling Starter Assembly

    STARTER SYSTEM CS-350WES 2-1 Disassembling starter assembly 1. Remove recoil starter assembly with front handle from unit. 2. Pull out starter rope about 30 centimeters (12 in) and hold rope reel (B). And pull starter rope inside starter case as shown.

  • Page 11: Replacing Starter Rope

    STARTER SYSTEM CS-350WES 2-2 Replacing starter rope 1. Pull out knot (A) and untie knot (A). 2. Pull out knot (C) from dent of rope reel (B). 3. When installing a new starter rope, singe both ends of the rope to prevent fraying.

  • Page 12: Assembling Starter

    STARTER SYSTEM CS-350WES 2-3 Assembling starter 1. When rewind spring (B) is released from rewind spring case (A), wind the released rewind spring from outside end on rewind spring case. 2. When replacing new rewind spring, remove spring holder after assembling rewind spring into rewind spring case (A).
  • Page 13 STARTER SYSTEM CS-350WES 2-3 Assembling starter (continued) 5. Make it sure engagement of rewind spring and rope reel by turning rope reel (F) clockwise and counterclockwise. 6. Install power spring meeting end (K) of power spring with hollow (H) of rope reel.

  • Page 14: Replacing Starter Pawl

    STARTER SYSTEM CS-350WES 2-3 Assembling starter (continued) 8. Fasten screw (P) on starter post. 9. Pull out starter rope inside starter case. Rotate rope reel clockwise several turns with rope hooked at notch (Q) as shown. Hold the rope reel to prevent it from rewinding and pull out starter grip out to take the rope slack.
  • Page 15 STARTER SYSTEM CS-350WES 2-4 Replacing starter pawl (continued) 3. Install washer, torsion spring, spacer, pawl, washer and bolt. To avoid pinching of torsion spring, install these parts without setting the hook (A) of torsion spring on starter pawl. The bolt is precoated with sealant on the thread.

  • Page 16: Ignition System

    IGNITION SYSTEM CS-350WES 3 IGNITION SYSTEM ( A ) Ignition switch ( B ) Stop lead ( C ) Spark plug ( D ) Spark plug cap coil ( E ) Spark plug cap ( F ) High tension lead...

  • Page 17: Troubleshooting Guide

    IGNITION SYSTEM CS-350WES 3-1 Troubleshooting guide Start Remedy Check Clean / Regap / Replace S.T. spark plug. Adjust pole shoe air gaps. Pole (Check flywheel magnet shoe air Clean / at the same time. Go to gaps Spark plug Regap / A if OK.)

  • Page 18: Testing Spark

    IGNITION SYSTEM CS-350WES 3-2 Testing spark 1. Remove spark plug cap from spark plug. Remove sprocket guard, guide bar and chain. 2. Connect spark tester 897800-79931 (A) to high tension lead and set crip (B) on spark plug. 3. Screw in adjuster (C) until the needle tips contact.

  • Page 19: Checking Ignition Switch And Leads

    IGNITION SYSTEM CS-350WES 3-4 Checking ignition switch and leads 1. Remove air cleaner cover. 2. Remove switch lead connector from ignition switch. Connect one probe of Ohm-meter or multi- meter to switch body, and other probe to switch terminal. 3. When ignition switch is in “RUN” position, the Ohm-meter should indicate infinite resistance.

  • Page 20: Replacing Ignition Switch

    IGNITION SYSTEM CS-350WES 3-5 Replacing ignition switch 1. Loosen nut (A), and remove ignition switch from carburetor case. 2. Put terminal (D) of ground lead on carburetor case as shown. Align notch (C) of new ignition switch (B) with tab of carburetor case, fasten nut (A) on the new ignition switch.

  • Page 21: Removing Ignition Coil

    IGNITION SYSTEM CS-350WES 3-7 Removing ignition coil 1. Disconnect switch lead from lead terminal of ignition coil. Loosen ignition coil bolts. 2. Remove cushion cap and loosen cushion rubber bolt. 3. Disconnect spark plug cap (C) from spark plug. Pass high tension lead through the space between engine cover (D) and rear handle (E).

  • Page 22: Installing Ignition Coil

    IGNITION SYSTEM CS-350WES 3-8 Replacing spark plug cap and coil (continued) 3. Pull the cap away from high tension lead (B). 4. Check spark plug cap coil (C) for correct connection, corrosion and the cap for cracks. Replace as required.

  • Page 23: Setting Pole Shoe Air Gaps

    IGNITION SYSTEM CS-350WES 3-10 Setting pole shoe air gaps 1. Insert 0.3 - 0.4 mm thick feeler gauge between flywheel and ignition coil. 2. Rotate flywheel until poles of flywheel face to ignition coil core. 3. Hold ignition coil against flywheel and tighten the screws.
  • Page 24 IGNITION SYSTEM CS-350WES 3-11 Replacing flywheel (continued) 7. Check woodruff key whether defective or sheared. Replace as required. 8. Wipe off oil from taper part of crankshaft before assembling flywheel. 9. lnstall woodruff key into key groove as shown. 10. Re-install starter pawls and all other removed parts on flywheel.

  • Page 25: Fuel System

    CS-350WES FUEL SYSTEM 4 FUEL SYSTEM ( A ) Cleaner lid ( B ) Air filter ( C ) Elbow ( D ) Carburetor ( E ) Nut ( F ) Fuel tank vent ( G ) Primer ( H ) Fuel strainer...

  • Page 26: Checking Air Filter

    FUEL SYSTEM CS-350WES 4-1 Checking air filter 1. Release hook (B) of cleaner lid (A) and remove air cleaner lid (A). 2. Turn air filter (C) counterclockwise and remove from elbow (D). 3. Check air filter (C) whether teared mesh or breakage.

  • Page 27: Checking Fuel Cap And Strainer

    CS-350WES FUEL SYSTEM 4-2 Checking fuel cap and strainer 1. Remove fuel cap. 2. Check fuel cap for cracks and O-ring (A) for cuts or damages. 3. Remove connector (B) if defective, install a new connector into center hole. 4. Pull fuel strainer (C) from fuel tank using a wire hook and clean the fuel strainer.

  • Page 28: Checking Fuel Tank And Pipe

    FUEL SYSTEM CS-350WES 4-3 Replacing primer (continued) 2. Push opposite side hook of hook (C) of primer using screw driver and push hook (C) by finger to remove primer. Remove fuel return pipe (D) from primer. 3. Before installing primer, connect fuel return pipe (D) to longer fitting (E) of new primmer.

  • Page 29: Checking And Replacing Fuel Vent

    CS-350WES FUEL SYSTEM 4-4 Checking fuel tank and pipe (continued) 5. Remove fuel cap, and remove fuel strainer from fuel pipe. 6. Connect pressure tester to the fuel pipe and apply pressure approx. 49 kPa (0.5 kgf/cm ) (7 psi).

  • Page 30: Replacing Fuel Pipe

    FUEL SYSTEM CS-350WES 4-5 Checking and replacing fuel vent (continued) 8. Reinstall tank vent to original position. 4-6 Replacing fuel pipe 1. Remove fuel cap. Remove fuel strainer and clip from fuel pipe. 2. Remove rear handle (Refer to section 9-3 Page 55).

  • Page 31: Removing Carburetor

    CS-350WES FUEL SYSTEM 4-6 Replacing fuel pipe (continued) 6. Install fuel pipe (C) and return pipe (D) on the grommet (E) as shown. 7. Install the assembled grommet on fuel tank. 275 mm 125 mm (10.8 in) (4.9 in) NOTE: Assemble grommet, as the pipe (D) is upper side of fuel pipe (C).

  • Page 32: Testing Carburetor

    FUEL SYSTEM CS-350WES 4-7 Removing carburetor (continued) 4. Disconnect inlet pipe (E) of primer and throttle rod (F) from carburetor. 4-8 Testing carburetor NOTE: To perform this test, inside carburetor should be wet. If it is not, there is a chance to be a little leakage.

  • Page 33: Checking Metering Lever Height

    CS-350WES FUEL SYSTEM 4-9 Checking metering lever height 1. Remove carburetor. 2. Remove metering diaghragm cover, metering diaghragm and gasket. 3. Check the metering lever height. Metering lever height : 1.65 mm (0.068 in) lower than (A) 4. If necessary, gently bend the lever up or down to set metering lever at correct position.

  • Page 34: Checking Inlet Needle Valve

    FUEL SYSTEM CS-350WES 4-11 Checking inlet needle valve 1. Remove metering lever pin with the lever (A), spring (C), and inlet needle valve (B). 2. Inspect inlet needle valve. If worn or sticky, clean or replace as required. NOTE: Causes of fuel flooding from carburetor to...

  • Page 35: Checking Crankcase Pulse Passage

    CS-350WES FUEL SYSTEM 4-13 Checking crankcase pulse passage 1. Drop a little oil in the pulse hole (a) on intake bellows (A). 2. Remove spark plug and pull starter grip several times. The oil should spit back from the hole.

  • Page 36: Adjusting Carburetor

    FUEL SYSTEM CS-350WES 4-14 Installing carburetor (continued) 3. Align idle adjust screw (M) of carburetor with hole of rear handle and insert fuel fitting (F) in fuel pipe (G). 4. Connect switch lead connector (H) to ignition switch (K). 5. Fasten elbow (L) and carburetor together with 2 screws.

  • Page 37: Presetting Idle Adjust Screw, L Mixture Needle And H Mixture Needle

    CS-350WES FUEL SYSTEM 4-15 Adjusting carburetor (continued) B. Adjust carburetor turning L and H mixture needles with limiter caps within the moving range (approx. : 90°) and idle adjust screw. When engine does not run correctly after this adjustment, proceed to the next step (4-15-1).
  • Page 38 FUEL SYSTEM CS-350WES 4-15-1 Presetting idle adjust screw, L mixture needle and H mixture needle (continued) 3. Screw thread side of limiter cap tool 91019 into center hole of the other limiter cap counterclockwise until the limiter cap is pulled out from the mixture needle completely.

  • Page 39: Adjusting Carburetor

    CS-350WES FUEL SYSTEM 4-15-2 Adjusting carburetor 1. Start engine and warm it up well for 2-3 minutes idle adjust screw with cycle of 5 seconds at WOT (Wide Open Throttle) and 10 seconds at idling. 2. Turn L mixture needle clockwise at idle speed slowly until engine speed drops.

  • Page 40: Clutch System

    CLUTCH SYSTEM CS-350WES 5 CLUTCH SYSTEM ( A ) Clutch assembly ( B ) Clutch plate ( C ) Clutch drum ( D ) Needle bearing ( E ) Washer ( F ) Clutch hub ( G ) Clutch shoe...

  • Page 41: Replacing Clutch Parts

    CS-350WES CLUTCH SYSTEM 5-2 Replacing clutch parts 1. Install tension spring (C) to the clutch shoes (B). 2. Set one arm of the clutch hub (A) to one guide of the clutch shoe. 3. Install other two guides of the clutch shoes on two arms as shown.

  • Page 42: Saw Chain Lubrication System

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 6 SAW CHAIN LUBRICATION SYSTEM ( A ) Oil outlet pipe ( B ) Auto-oiler assembly ( C ) Worm gear ( D ) Oil intake pipe ( E ) Oil filter (Strainer) ( F ) Engine cover (Oil tank)

  • Page 43: Checking Oil Pipe

    CS-350WES SAW CHAIN LUBRICATION SYSTEM 6-2 Checking oil pipe 1. Remove guide bar, chain and sprocket guard. 2. Remove chain catcher, spiked bumper and sprocket guard plate. 3. Disconnect lower oil pipe (A) from auto-oiler assembly and connect pressure tester 897803- 30133 (B) to oil pipe (A).

  • Page 44: Replacing Oil Pipe And Grommet

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 6-4 Replacing oil pipe and grommet 1. Remove oil pipe and grommet from engine cover. 35mm 2. Insert new oil pipe to the grommet as shown. (1.4 in) NOTE: Apply sealant (Loctite #424 or equivalent) into hole of grommet to prevent oil pipe from moving.

  • Page 45: Installing Worm Gear

    CS-350WES SAW CHAIN LUBRICATION SYSTEM 6-7 Installing worm gear 1. Put new worm gear on the crankshaft end. 2. Setting circular washer (D) on end of worm press tool (C) and screw bar tool (A) on thread of crankshaft counterclockwise.

  • Page 46: Engine

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 7 ENGINE ( A ) Crankcase (Cylinder) ( B ) Crankcase ( C ) Crankshaft ( D ) Ball bearing ( E ) Oil seal ( F ) Engine cover ( G ) Piston ring...

  • Page 47: Cleaning Cooling Air Passage

    CS-350WES SAW CHAIN LUBRICATION SYSTEM 7-1 Cleaning cooling air passage 1. Remove starter assembly with front handle from engine body. WARNING DANGER Always wear eye protection when using com- pressed air for cleaning. Otherwise, eye damage can occur from flying patricles Remove ignition coil for cleaning cylinder fins easily.

  • Page 48: Testing Cylinder Compression

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 7-3 Testing cylinder compression NOTE: Test the cylinder compression when engine is cold. 1. Move ignition switch to STOP position. 2. Remove spark plug. 3. Install a compression gauge 91007 (A) into spark plug hole and pull starter several times to stabilize reading.

  • Page 49: Removing Engine Block

    CS-350WES SAW CHAIN LUBRICATION SYSTEM 7-5 Removing engine block 1. Remove clutch assembly, auto-oiler, ignition coil, flywheel and rear handle. 2. Remove dust cover and loosen bolts (A) fastening cylinder and bolts (B) on back side of the unit. 3. Remove intake bellows.

  • Page 50: Checking Piston And Piston Ring

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 7-7 Checking piston and piston ring 1. Check piston ring and replace it if broken, scored, or exceed service limits. Refer to 1-5. 2. Inspect piston crown and ring groove, and clean with fine sand paper, oil stone, or ring groove cleaning tool if carbon is deposited.

  • Page 51: Replacing Oil Seal And Ball Bearing

    CS-350WES SAW CHAIN LUBRICATION SYSTEM 7-9 Replacing oil seal and ball bearing 1. Check oil seal(s) and replace if defective. 2. Check ball bearing(s) for smooth rotation. If not, remove ball bearing(s) using bearing wedge (A) 897701-02830. NOTE: When removing the oil seal or ball bearing at clutch side, worm gear should be removed in advance.

  • Page 52: Installing Piston Into Cylinder

    SAW CHAIN LUBRICATION SYSTEM CS-350WES 7-11 Installing piston into cylinder 1. Apply 2-stroke oil inside cylinder, groove of oil seal, piston ring, ball bearing and both sides of con- rod. 2. Meet end gap of piston ring with locating pin (B).

  • Page 53: Chain Brake System

    CS-350WES CHAIN BRAKE SYSTEM 8 CHAIN BRAKE SYSTEM ( A ) Brake lever ( B ) Screw ( C ) Collar ( D ) Collar ( E ) Lock nut ( F ) Brake connector ( G ) Brake cover...

  • Page 54: Assembling Brake Parts

    CHAIN BRAKE SYSTEM CS-350WES 8-2 Assembling brake parts 1. Install pin (B) through brake band (A) hole. Assemble the brake band together with pin (B), compression spring (C), spacer (D) and brake connector (E) to sprocket guard as shown. 2. Apply molybdenum grease on whole of compression spring (C) and friction part of other parts.

  • Page 55: Handle And Control System

    HANDLE AND CONTROL SYSTEM CS-350WES 9 HANDLE AND CONTROL SYSTEM 9-1 Removing front handle 1. Remove screws securing front handle (A) on clutch side. 2. Remove cap (B) in handle cushion of starter side, and loosen cushion bolt and remove front handle (A) from unit.

  • Page 56: Removing Rear Handle

    HANDLE AND CONTROL SYSTEM CS-350WES 9-2 Installing front handle (continued) 5. Install cap (B) as shown. 6. Tighten screws securing front handle (clutch side). 9-3 Removing rear handle 1. Remove front handle with stater assembly. 2. Remove air cleaner cover, air filter elbow and carburettor.
  • Page 57 HANDLE AND CONTROL SYSTEM CS-350WES 9-3 Removing rear handle (continued) 5. Remove collar (E) from intake bellows (D). 6. Loosen nut securing switch (F) and remove ignition switch (F) from rear handle (G). Remove primer from rear handle and remove return pipe from primer.

  • Page 58: Replacing Throttle Trigger

    HANDLE AND CONTROL SYSTEM CS-350WES 9-3 Removing rear handle (continued) 9. Removing pulse pipe (M) from crankcase fitting, remove rear handle (G) from engine cover. 9-4 Replacing throttle trigger 1. Loosen screw (A) securing handle cover, and remove handle cover (B).
  • Page 59 HANDLE AND CONTROL SYSTEM CS-350WES 9-4 Replacing throttle trigger (continued) 3. Set torsion spring (F) and throttle rod (H) on throttle trigger (E) as shown. 4. Install the throttle trigger (E) with torsion spring and throttle rod on rear handle (K) and insert throttle shaft (D) as follows.

  • Page 60: Installing Rear Handle

    HANDLE AND CONTROL SYSTEM CS-350WES 9-5 Installing rear handle 1. Apply oil on flange (A) of pulse pipe and install it in the hole of rear handle. 2. Apply oil on 2nd flange of short fuel pipe (B) and pull it in the hole of rear handle using long nose pliers with taking care of damage.
  • Page 61 HANDLE AND CONTROL SYSTEM CS-350WES 9-5 Installing rear handle (continued) 4. Put rear handle (D) on engine cover, pass return pipe (E), lead (F) and ground lead (G) through hole of rear handle as shown. 5. Insert pulse pipe until upper eye mark (H) faces with level of dust cover (K).
  • Page 62 HANDLE AND CONTROL SYSTEM CS-350WES 9-5 Installing rear handle (continued) 7. Install intake bellows (N) and intake pipe (O) on rear handle, using blade screw driver with taking care of damage. Install collar on intake bellows (N). 8. Tighten cushion bolts in rear handle front side cushion (P), rear handle rear side cushion (Q) and starter side cushion (R).
  • Page 63 HANDLE AND CONTROL SYSTEM CS-350WES 9-5 Installing rear handle (continued) 9. Connect return pipe (E) to primer. 10. Set pipes and leads at correct positions respectively, and install carburetor and all other removed parts.

  • Page 64: Guide Bar Mounting System

    CUIDE BAR MOOTING SYSTEM CS-350WES 10 GUIDE BAR MOUNTING SYSTEM ( A ) Sprocket guard ( B ) Sprocket guard plate ( C ) Tensioner screw ( D ) Bevel gear ( E ) Chain tensioner ( F ) Collar...

  • Page 65: Replacing Guide Bar Stud

    CS-350WES CUIDE BAR MOOTING 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. 3. If hard to remove or the stud is broken and too...

  • Page 66: Maintenance Guide

    MAINTENANCE GUIDE CS-350WES 11 MAINTENANCE GUIDE 11-1 Disassembly Chart Guide bar Front Starter Air cleaner Spark plug Muffler cover handle assembly (3-3,3-8) cover (10-1) (9-1) (2-1) (4-1) Clutch Exhaust Front side Ignition Air filter assembly Muffler cushion switch (4-1) (5-1)

  • Page 67: Troubleshooting Guide

    CS-350WES MAINTENANCE GUIDE 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 extremetly noisy.
  • Page 68 MAINTENANCE GUIDE CS-350WES 11-2 Troubleshooting guide (continued) CHECKING REFERENCES Check first. Fuel system / Carburetor 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 Air filter Fuel cap / filter Carburetor adjustment 4-15 Fuel tank / line/ vent...

  • Page 69: Service Intervals

    CS-350WES MAINTENANCE GUIDE 11-3 Service Intervals Intervals 3 months 6 months Yearly Check point Service Reference Daily 100 hours 300 hours 600 hours Screws, bolts, and nuts Inspect / Retighten / Replace Air filter Clean Replace Carburetor Inspect / Rebuild...

  • Page 70: Index

    INDEX INDEX CS-350WES Adhesive 4, 50, 63 Ground lead 14, 17, 59 Pole shoe air gaps 3, 21 Air filter 24 Grease 4, 10, 43, 52, 53 Primer 26 Auto-oiler assembly 42, 43 Grommet, fuel tank 26, 29 Pulse pipe 56, 58, 59...
  • Page 71 Printed in Japan TOKYO JAPAN 0506...

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