Echo CS-2511TES, Service Manual

Page 1: ...Ref No 401 40 CS 2511TES ECHO shindaiwa 251Ts 251TCs Serial number 37000001 and after...

Page 2: ...ing guide that describes problems testing remedies and references We recommend you make use of Operator s Manual and Parts Catalogue together with this manual when servicing We are constantly working...

Page 3: ...inlet needle valve 39 4 13 Inspecting diaphragm and others 40 4 14 Replacing welch plug 40 4 15 Installing carburetor 41 5 CLUTCH SYSTEM 42 5 1 Inspecting clutch parts 42 5 2 Replacing clutch parts 44...

Page 4: ...x 720 0 12 x 28 3 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Petrol Minimum 89 octane petrol Two stroke air cooled engine oil ISO L EGD ISO CD13738 JASO FC FD Tank capacity L UK fl oz 0 1...

Page 5: ...l sec 5 5 100 2 Find idle maximum speed Adjust L mixture needle to maximum idle speed 2 3 Set idle maximum speed w TAS r min 4 000 4 Set idle speed by turning L mixture needle ACW r min 3 200 2 800 3...

Page 6: ...4 25 35 Front handle rear side M4 20 30 2 3 20 25 Spring M4 20 35 2 3 5 20 30 Brake cover M4 20 30 2 3 20 25 Sprocket guard plate Sprocket guard side M4 20 30 2 3 20 25 Brake lever Hand guard M5 30 45...

Page 7: ...375 C Piston pin bore Max 8 035 0 3163 D Piston ring groove Max 1 3 0 051 E Piston ring side clearance Max 0 1 0 004 F Piston pin outer diameter Min 7 98 0 3142 G Piston ring width Min 1 15 0 045 H Pi...

Page 8: ...plug from auto oiler assembly 13 91037 Compression gauge Measuring cylinder compression 14 X681 051690 Adapter M10 Measuring cylinder compression for 10mm dia spark plug 15 897826 16131 Pressure rubb...

Page 9: ...n cylinder 6 When accumulated energy in power spring F overcomes the load from compression pressure in cylinder crankshaft is rotated 7 Power spring F absorbs compression resistance of cylinder and sn...

Page 10: ...n rope reel notch c as shown 4 Rotate rope reel C counterclockwise to release tension of rewind spring 5 Remove screw D 6 Remove pawl catcher E and power spring F 7 Remove rope reel C from starter cas...

Page 11: ...rope through hole of rope reel C then press the knot D into recess as shown 3 When installing a new starter rope singe both ends of the rope to prevent fraying 5 Pass the other end of starter rope th...

Page 12: ...case B before wind the spring 2 Carefully install rewind spring case assembly C on starter case matching hole c with post D Hook a of rewind spring should contact with post E of starter case 3 Wind th...

Page 13: ...f4 9 Install pawl catcher J engaging hole j with power spring top end hook h2 10 Reinstall screw K on starter post 11 Pull out starter rope inside starter case Rotate rope reel F clockwise 3 turns wi...

Page 14: ...rter assembly from unit 2 Loosen bolt A and remove pawl B and torsion spring C Replace damaged or worn parts NOTE When it is hard to loosen bolt install clean rope D in spark plug hole E to stop crank...

Page 15: ...YSTEM CS 2511TES 251Ts 251TCs 13 3 IGNITION SYSTEM A Ignition switch B Spark plug C Spark plug cap coil D Spark plug cap E Ignition coil F Bolt M4 G Collar H Flywheel J Nut M8 K Woodruff key B C D E H...

Page 16: ...Not OK Not OK S T OK S T Not OK Pole shoe air gaps Replace OK OK Leads connections Not OK OK OK Not OK S T Repair Replace Not OK Remedy Inspect Not OK Woodruff key End Not OK Flywheel magnet Replace R...

Page 17: ...gnition switch to RUN position Pull start er grip several times 6 If spark is steady blue or white at the tester gap ignition system is considered good 7 If no spark exists or spark is intermittent in...

Page 18: ...y If it is exces sively wet or dry inspect fuel system A B 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 fr...

Page 19: ...ster should indicate infinite resistance 4 When ignition switch is in STOP position tes ter should show that the circuit is in conducting state closed circuit 5 If ignition switch is defective replace...

Page 20: ...ing ignition switch Continued 4 Loosen nut F and remove sprocket guard G 5 Remove bolt H chain catcher J and sprocket guard plate K 6 Remove bolt L and brake lever M 7 Remove plug N and bolt P 8 Remov...

Page 21: ...assing switch lead t1 and t2 through notch on rib U1 U2 and U3 11 Insert rear part of rear handle lid R to hole v1 on rear handle assembly V as shown 12 Assemble rear handle lid R as rib v2 on rear ha...

Page 22: ...tion coil 3 8 Setting pole shoe air gaps 17 Pass switch lead t1 for terminal B through notch X then pass switch lead t2 for terminal C over the lead t1 18 Set switch lead t1 and t2 between engine cove...

Page 23: ...nued 22 Insert front starter side tab e2 on dust cover into engine cover 23 Insert rear clutch side tab e3 on dust cover into engine cover 24 Insert front clutch side tab e4 on dust cover into engine...

Page 24: ...l spark plug cap and spark plug cap coil to new ignition coil F 8 Apply a drop of thread locking sealant Loc tite 222 or ThreeBond 1344J or equivalent to tapped hole H of cylinder 9 Set collars J as s...

Page 25: ...004 B or feeler gauge NOTE When air gap is too narrow contact with flywheel may result When the air gap is too wide spark is weak 4 Reassemble all removed parts D C A 3 9 Inspecting flyweel and key 1...

Page 26: ...r alternately to remove flywheel A 8 Inspect woodruff key H for damage or shear ing Replace as required 9 Wipe off oil from taper part of crankshaft and fly wheel before assembling flywheel 10 Install...

Page 27: ...Connector F Fuel tank G Fuel tank vent H Fuel strainer J Clip K1 Fuel line in fuel tank K2 Fuel line 3x5x95mm K3 Fuel line L Grommet M Joint L shaped black N Joint black P Purge line L shaped Q Purge...

Page 28: ...ir cleaner cover D 5 Turn air filter E counterclockwise and remove it 6 Inspect air filter E If blocked with dirt or dust remove the obstruction with using brush 7 If heavily blocked with dirt or dust...

Page 29: ...air coming into engine can be blocked To find such oil take the following a Disassemble air filter assy b Touch air filter mesh by finger tip from oppo site side c If your fingerprint is clearly show...

Page 30: ...ut from fuel tank using a wire hook D Clean fuel strainer C Replace with new one if defective or heavily soiled 5 Reinstall fuel cap A B C D 4 2 Replacing air cleaner cover latch 1 Turn lifting hook A...

Page 31: ...E Wrap the ends of longnose pliers with tape J or cover with soft pipes to protect fuel line from damage 6 Apply pressure approx 50 kPa 0 5 kgf cm2 7 psi 7 If pressure drops replace with new fuel line...

Page 32: ...from grommet B 3 Connect tank vent A to pressure tester 91139 C 4 Apply pressure approx 50 kPa 0 5 kgf cm2 7 psi Make sure pressure is stable in range of 10 40 kPa 0 1 0 4 kgf cm2 1 4 5 7 psi 5 If it...

Page 33: ...nge gently clean tank vent with compressed air or replace with new one NOTE Do not disassemble valves in tank vent as sembly Damage to valves will occur 4 Remove cap C of tank vent and clean sponge D...

Page 34: ...etor 3 Press leg a1 of purge bulb A with screwdriver to remove purge bulb A from rear handle 4 Disconnect parge line B and fuel return line C from purge bulb A Installing 5 Connect fuel return line C...

Page 35: ...remove fuel line D black joint B and fuel return line H from grommet K 6 Inspect fuel line D joint B fuel return line H and grommet K Replace with new one if defec tive 7 To replace fuel line M and fu...

Page 36: ...ward fuel tank side NOTE Push black joint B in grommet K as brim b of joint B touches grommet K 16 Adjust direction of fuel line A and joint B as view R 17 Reinstall fuel return line H through grommet...

Page 37: ...correctly after this adjustment proceed to the next step 4 8 2 4 8 2 Initial setting Throttle adjust screw L mixture needle and H mixture needle Tools Required P N G310 000050 Tachometer PET 304 P N...

Page 38: ...L mixture needle to assure accurate tachometer readings 5 Before adjustment WOT engine speed should be 12 000 r min or less If engine speed is higher turn H mixture needle C counterclockwise until 12...

Page 39: ...essure drops at step 3 or if pressure drops below standard figure at step 5 remove carburetor from the unit as step 8 9 and 10 8 Remove air cleaner cover and air filter 9 Remove two bolts D carburetor...

Page 40: ...one as required B A 4 11 Inspecting metering lever height 1 Remove carburetor 2 Remove four screws A metering diaphragm cover B metering diaphragm C and gasket D 3 Inspect metering lever E height by...

Page 41: ...follows Improper assembling of metering lever and spring Dirt between inlet needle valve and valve seat Worn inlet needle valve tip 3 Clean inlet needle valve seat using suitable clean solvent do not...

Page 42: ...H needle clockwise until lightly seated and remove inlet needle valve Otherwise main nozzle check valve and inlet needle valve spring may be damaged by the compressed air 9 Reassemble removed parts w...

Page 43: ...throttle rod A to throttole lever B 2 Connect purge line C and joint D on carbure tor and install fuel inlet E to fuel line F 3 Pass purge line C through tab G as shown 4 Fasten carburetor and carbure...

Page 44: ...sen nut A and remove sprocket guard B NOTE If starter assembly is installed pull starter rope out about 20 cm 8 in and make a tempo rary knot to prevent starter damage when installing clutch assembly...

Page 45: ...utch hub L and clutch shoes M If their clearances are large re place with new parts 8 Inspect circumuferences m1 and holes m2 hooked springs N for wear Replace with new parts as required 9 Inspect clu...

Page 46: ...sembly is installed untie tempo rary knot holding starter grip tied in the first NOTE of 5 1 Inspecting clutch parts While holding starter grip turn clutch assembly counterclockwise untill it cannot r...

Page 47: ...procket guard F Collar G Brake connector H Pin J Brake band K Spacer L Compression spring M Brake cover N Bolt M4 C D E G J A K L M 6 1 Replacing brake lever and torsion spring Disassembling 1 Remove...

Page 48: ...m brake lever F 5 Check brake lever F if broken and torsion spring G if deformed or broken Replace with new part s if defective Assembling 6 Assemble torsion spring G as shown 7 Put hole f of brake le...

Page 49: ...make brake connector engaging position NOTE Make sure that brake connector A is in engaging position before removing brake cover C otherwise compression spring may jump out 3 Remove bolt D and sprocke...

Page 50: ...guard as shown Note Make sure notch m of spacer M places as shown 9 Push compression spring N with driver or other suitable tool and install compression spring N in sprocket guard as shown 10 Install...

Page 51: ...washer M Worm gear N Oiler cover F G H A K L K B C E M N D 7 1 Inspecting oil cap and strainer 1 Remove oil cap 2 Inspect oil cap for cracks and gasket A for cuts or damage Replace worn or damaged pa...

Page 52: ...chain oil in the tank is con sumed 1 Remove starter assembly 2 Push oil tank vent A into oil tank using suitable tool and take out vent A from oil tank 3 Clean oil tank vent A 4 Check that oil tank v...

Page 53: ...to use pipe joint V186 000020 F 6 Tighten oil cap and apply pressure approx 9 8 kPa 0 1kgf cm2 1 4psi 7 Pressure should not drop If the pressure drops leakage may occur at oil line oil cap oil cap ga...

Page 54: ...d circular washer B 3 Inspect worm gear A and circular washer B for damage wear or deformation Replace with new part s as required NOTE If worm gear A is dameged inspect gear of auto oiler assembly Re...

Page 55: ...to step 7 When plunger gear E can not be rotated go to step 14 7 Prepare ethanol F in container 8 Install new worm gear G to auto oiler B Set clutch drum H on worm gear G engaging sprocket h with two...

Page 56: ...move the plug K 18 Pull out spring pin J from adjuster needle K with plier 19 Pull out adjuster needle K and spring L from auto oiler body 20 Remove plunger gear E circular washer R spring S and circu...

Page 57: ...inger from plunger gear E 28 Press adjuster needle K to the bottom orient ing the flat surface k1 as shown This position indicates maximum discharge volume of chain oil 29 Tap new spring pin J into ho...

Page 58: ...ankshaft H Needle bearing J Piston pin spacer K Piston pin A D F H K E J L L M N O P R R Q S T U V V W X Y Z L Snap ring M Piston N Piston ring O Cylinder P Cylinder piece Q Gasket Cylinder R Bolt M4...

Page 59: ...several times to stabilize reading on compression gauge 6 If pressure is lower than approx 75 of standard compression pressure Refer to 1 2 Technical data inspect cylinder bore piston and piston ring...

Page 60: ...and or saw dust D Clean them with wooden or plastic stick or compressed air as re quired 4 Remove ignition coil E if cylinder fins are hard to clean Inspect the clearance of cylinder fins and the clea...

Page 61: ...F if carbon is found NOTE When cleaning exhaust port always posi tion piston at Top Dead Center TDC to prevent carbon from entering cylinder Do not use metal tool and be careful not to scratch piston...

Page 62: ...E for carburetor 3 To seal exhaust port of cylinder cut pressure rubber plug 91041 F off as shown 4 Remove exhaust plate and muffler G with ex haust gasket H Refer to 8 3 Inspecting muffler and exhau...

Page 63: ...oapy water to locate leakage 13 Then apply negative pressure approx 30 kPa 0 3 kgf cm2 4 4 psi by pressure tester and leave for 30 seconds 14 If the reading drops leakage may occur from oil seal Inspe...

Page 64: ...rd to remove cylinder B gently tap both crankshaft ends using plastic mallet C to remove crankcase assembly with crankshaft and piston assembly holding cylinder B 2 Inspect cylinder combustion chamber...

Page 65: ...use square end of broken piston ring when cleaning piston ring groove otherwise piston ring groove might be damaged 4 Remove snap rings F from both sides of piston pin 5 Push piston pin G out from pis...

Page 66: ...usher adapter K stamped 8 12 Install new snap rings on both end of piston pin Make sure that they are properly seated in snap ring grooves NOTE Always use new snap rings 13 Install piston ring on pist...

Page 67: ...use puller Y089 000110 G prepared as follows 1 Drill two 6mm dia holes on puller Y089 000110 G as below 2 Three screws or bolts 91311 04075 H size M4x75mm lengh pitch 0 7mm 3 Three nuts 900500 00004...

Page 68: ...ve ball bearing C Oil seal B remains in crankcase bore 5 Push out oil seal B with using oil seal tool 897726 09130 E Assembling 6 Set new ball bearing C with shaft A adapter F inner dia 15 mm outer di...

Page 69: ...TE Make sure to match hole position D of crankcase gasket C and clutch side crankcase half B 4 Reassemble both crankcase halves together en suring that dowel pins b on clutch side crankcase half B are...

Page 70: ...avenging port b1 of cylinder as shown 3 Set new cylinder gasket C on cylinder B as notch c1 of gasket C aligns pulse hole b2 4 Install piston ring D on piston E ensuring the end gaps of piston ring ar...

Page 71: ...handle B Rear handle C Rear handle lid D Torsion spring E Throttle trigger F Throttle lockout G Throttle rod H Plug J Bolt M5 K Bolt M4 L Spring M Bolt M4 N Bolt M4 P Spring C D E F A G H J K M L N P...

Page 72: ...le D and replace it if broken or deformed Refer to 9 4 Replacing rear handle and springs Inspecting lifting hook bracket 5 Lifting hook bracket E is installed rear handle D as shown If the following d...

Page 73: ...om lifting hook bracket E pushing lifting hook F to starter side 2 Remove starter side hook end F2 on lifting hook F from lifting hook bracket E 3 Insert starter side hook F2 on new lifting hook F to...

Page 74: ...rod F from carburetor 7 Check throttle control parts and replace defec tive part s with new one as required Assembling 8 Insert throttle rod F to rear handle J and con nect throttle rod F to carburet...

Page 75: ...dle C as shown and remove it from rear handle D 5 Remove bolt F and spring G Assembling 6 Install spring G to rear handle D and tighten screw F as shown NOTE Make sure to set spring G inside projec ti...

Page 76: ...ing carburetor two plugs A collor B and C inserted intake bellows 6 Remove purge bulb and fuel line assembled rear handle Refer to 4 6 Replacing purge bulb and 4 7 Replacing fuel line and fuel return...

Page 77: ...ed parallel to line g3 of rear handle G If spring J is in an upward direction loosen bolts and retighten them 18 Insert two plugs A to rear handle G 19 Insert collar B and C to intake bellows L 20 Ass...

Page 78: ...ing rear handle and springs continued 25 Insert rear part of rear handle lid N to hole g4 on rear handle G as shown 26 Assemble rear handle lid N as rib g5 on rear handle G enters into rear handle lid...

Page 79: ...L Bolt M5 M Sprocket guard plate N Stud bolt C D E F A G H J K L M N 10 1 Replacing nut for fixing guide bar Disassembling 1 Pinch hook A with pliers B and remove hook A and nut C from sprocket guard...

Page 80: ...place with new part s as required Assembling 3 Install bevel gear G into sprocket guard H 4 Screw chain tensioner E on tensioner screw D 5 Put bevel gear F on tensioner screw D 6 Install sub assembled...

Page 81: ...ockwise 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...

Page 82: ...ion is excessive Engine does not stop Oiler does not function Saw chain does not cut well INSPECTING Starter system Starter drum rope Ignition system Sparks Spark plug Spark plug cap coil Ignition swi...

Page 83: ...3 1 2 8 1 8 4 1 5 8 6 8 9 1 5 8 7 Fuel tank line vent Purge bulb 4 4 to 4 7 INSPECTING 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 REFERENCES Carburetor...

Page 84: ...ter 4 1 Carburetor 4 9 4 15 Clutch drum 5 1 5 3 Ignition switch 6 1 Brake lever Rear handle lid 9 2 8 9 8 11 Crankshaft Spark plug 3 2 3 3 Clutch ASY 5 1 to 5 3 Sprocket guard Throttle control parts 9...

Page 85: ...5 3 6 Fuel tank Clean inside 4 4 Muffler and exhaust port Clean 8 3 Starter system Inspect Repair 2 1 to 2 4 Oil tank Clean inside Oil strainer Clean Replace 7 1 Sprocket Inspect Replace 1 5 5 1 Guid...

Page 86: ...tion coil 4 13 14 22 23 80 82 Ignition switch 4 13 14 17 to 21 80 82 Ignition system 2 3 13 Ignition timing 3 Inlet needle valve 39 81 Intake bellows 4 38 61 82 Key flywheel 13 23 24 80 L mixture need...

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Page 88: ...Published by YAMABIKO Corp Tokyo Japan 1610...