CS-4400, CS-5100
Contents
1. gt 89 octane RON and properly mixed at 50 1 with ISO L EGD 2 stroke oil The recommended bar and chain must be installed to the power head and properly tensioned NOTE Make sure of proper installation of 45 cm guide bar and saw chain when adjusting carburettor or serious engine damage may occur due to overspeeding 2 2 Presetting idle adjust screw L mixture needle and H mixture needle 1 Tools x ug extractor body B 2 5mm Hexagonal socket O C Nut D 1 5mm blade screw driver E L wrench 2mm F 2 5mm hand tap G Magneto spanner 6mm 2 Remove carburettor from unit 3 Make M2 5 x 0 5mm pitch thread using M2 5 hand tap 4 Fit the nut C on hex socket bolt B near the bolt head Place extractor body over the limiter cap Pass the bolt B with nut C through the hole of the extractor body and screw the bolt in the limiter cap 5 turns C B Locating pin 1 P CS 4400 SERVICE INFORMATION CS 5100 CS 5100 2 2 Presetting idle adjust screw L mixture needle and H mixture needle continued 5 While holding bolt with L wrench turn the nut clockwise to take out the limiter cap 6 Repeat step No 3 to No 5 for other limiter cap removal 7 Temporally insert new limiter caps on both L and H mixture needle by aligning groove on limiter cap B to locating pin A on extension housing Make it sure that limiter cap face is leveled with extension housing top2. 40 Chain catcher M5 30 45 3 0 4 5 26 40 Guide bar M8 200 230 20 23 175 200 Sprocket guard plate M 4 10 20 1 2 9 17 Regular bolt nut M3 6 10 0 6 1 0 5 9 and screw M4 15 25 1 5 2 5 13 22 M5 25 45 2 5 4 5 22 40 M6 45 75 4 5 7 5 40 65 LM Left hand thread Apply thread locking sealant See next page Tapping screw t The torque differences among four bolts should not exceed 20 kgf cm 2Nm 17inelbf on one cylinder or crankcase CS 4400 CS 5100 SERVICE INFORMATION 1 4 Special repairing materials Material Location Remarks Adhesive Ball bearing outer crankcase Loctite 675 or equivalent Stud bolt Loctite 609 ThreeBond 1373 or equivalent Engine cover cushion Loctite 406 424 or equivalent Liquid gasket Crankcase seams Loctite 515 990610 00051 or equivalent Oil tank seams Loctite superflex 595 ThreeBond 1212 or equivalent Thread locking sealant Starter pawl screws Loctite 242 ThreeBond 1324 or equivalent Cushion screws Rear handle Engine mount bolts Brake weight nut Crankcase Loctite 222 ThreeBond 1342 or equivalent Grease Auto oiler worm Clutch needle bearing Cushion inside Rewind spring Oil seal lip Cleaner lid Lithium based grease Chain brake metal contact part Molybdenum grease approx 1 gram 6 1 5 Service Limits CS 4400 SERVICE INFORMATION CS
3. 4400 CS 5100 KA z 5K178 DT SA 5K191B mm in A Cylinder bore When plating is worn and aluminium can be seen B Piston outer diameter Min 1 688 C Piston pin bore Max 0 3553 D Piston ring groove Max 0 051 E Piston ring side clearance Max 0 004 F Piston pin outer diameter Min 0 3535 G Piston ring width Min 0 045 H Piston ring end gap Max 0 02 K Con rod small end bore Max 0 4774 L Crankshaft runout Max 0 002 M Sprocket bore Max 0 5146 N Clutch drum bore Max 2 81 P Sprocket wear limit Max 0 02 CS 4400 CS 5100 1 5 Service Limits CS 5100 SERVICE INFORMATION mm in A Cylinder bore When plating is worn and aluminium can be seen B Piston outer diameter Min 44 89 1 767 C Piston pin bore Max 11 025 0 4341 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 10 980 0 4323 G Piston ring width Min 1 15 0 045 H Piston ring end gap Max 0 5 0 02 K Con rod small end bore Max 15 025 0 5915 L Crankshaft runout Max 0 05 0 002 M Sprocket bore Max 15 07 0 5933 N Clutch drum bore Max 71 5 2 81 P Sprocket wear limit Max 0 5 0 02 8 1 6 Special tools 2a 3mm CS 4400 SERVIC
4. Do not press limiter cap deeper at this moment Groove 8 Turn L and H mixture needles clockwise until lightly seated using 1 5mm blade screw driver and then turn both needles anticlockwise for following turns L mixture needle 1 1 2 H mixture needles 2 1 4 Even at this stage do not press limiter caps in 9 Reinstall the carburettor on the unit CS 4400 1 3 CS 5100 SERVICE INFORMATION CS 5100 2 3 Adjusting carburettor 1 Start engine and warm it up well for 2 3 minutes with cycle of 5 seconds at WOT Wide Open Throttle and 10 seconds at idling 2 Using 1 5 mm wide blade screw driver adjust L mixture needle to obtain maximum idle speed 3 Set idle speed to 3 500 r min by turning idle adjust screw in the range of 3 300 to 3 700 r min allowable 4 Turn L mixture needle anticlockwise to reduce engine idle speed 1000 r min to set idle speed in the range of 2 300 to 2 700 r min NOTE Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings 5 Turn H mixture needle anticlockwise at WOT until engine speed drops less than 12 000 r min 6 Adjust WOT engine speed in the range of 12 500 to 13 500 r min by turning H mixture needle clockwise NOTE During H mixture needle adjustment do not run engine at high speed without load longer than 5 seconds 7 lf the engine speed at WOT is above 13 500 r mi
5. until lightly seated and then turn out both needles following turns L mixture needles 1 1 4 H mixture needles 3 NOTE If needles are forced during seating damage to carburettor may occur 6 Turn idle adjust screw anticlockwise and set the screw until the tip to just contact throttle plate Then turn idle adjust screw 1 1 2 turns clockwise 1 O CS 4400 SERVICE INFORMATION CS 5100 CS 4400 2 3 Adjusting carburettor 1 Start engine and warm it up well for 2 3 minutes with cycle of 5 seconds at WOT Wide Open Throttle and 10 seconds at idling 2 Using 2 5 mm wide blade screw driver adjust L mixture needle to obtain maximum idle speed 3 Set idle speed to 3 500 r min by turning idle adjust screw in the range of 3 300 to 3 700 r min allowable 4 Turn L mixture needle anticlockwise to reduce engine idle speed 1000 r min to set idle speed in the range of 2 300 to 2 700 r min NOTE Engine speed must be allowed to stabilize a minimum of 20 seconds after each adjustment of L mixture needle to assure accurate tachometer readings 5 Turn H mixture needle anticlockwise at WOT until engine speed drops less than 11 000 r min 6 Adjust WOT engine speed in the range of 11 500 to 13 000 r min by turning H mixture needle clockwise NOTE During H mixture needle adjustment do not run engine at high speed without load longer than 5 seconds 7 If the engine speed at WOT is above 13 000r min adjust
6. 01 44C 01 CS 4400 CS 5100 UUELGHE SERVICE DATA CHAIN SAW CSs 4400 CSs 517100 Serial number 36000001 and after INTRODUCTION We are constantly working on technical improvement of our products For this reason technical data equipment and design are subject to change without notice All specifications illustrations and directions in this SERVICE DATA are based on the latest products information available at the time of publication ECHO SERVICE MANUAL Ord 401 21 Model CS 4200 CS 4400 contains lots of information for servicing this model E KIORITZ CORPORATION INDEX CONTENTS page 1 SERVICE INFORMATION c 0ecseee 2 1 1 Specification c cece ceecesseeceseeceeeseeeeeeeees 2 1 2 Technical data cccccccecceeeceeeeeeeeeeeeeeeeees 3 1 3 Torque limits 22 0 0 eecceecceeeeeeeeeeeeeeeeneeens 4 1 4 Special repairing materials 68 5 1 5 Service liM tS asa cccunniaccocanoansscacimanenovmmoannessive 6 1 6 Special tools ccccccccccseecceeeeeeeeeeeeeeeeaees 8 2 EMISSION ADJUSTMENT GUIDE 9 CS 4400 2 1 General adjusting rules ccceeeeeeeeees 9 2 2 Presetting idle adjust screw L mixture needle and H mixture needle ccccseeeseeeeeeeeeeeeees 9 2 3 Adjusting idle speed and WOT speed 10 CS 5100 2 1 General adjusting rules ccceeeeeeee 11 2 2 Presetting idle adjust screw L mixtu
7. E INFORMATION CS 5100 4 5 6 0 A 0D O O TF Key Part Number Description Used for 1 897801 33330 Tachometer PET 1000 Measuring engine speed to adjust carburettor 2 895612 79920 L hex wrench 3 mm Removing and installing hex socket bolt M4 3 895610 79920 L hex wrench 4 mm Removing and installing hex socket bolt M5 4 897501 03938 Puller Removing magneto rotor 5 897505 16133 Clutch tool Removing and assembling clutch assembly 6 897537 30130 Piston stopper Locking crankshaft rotation 7 897563 19830 Metering lever gauge Measuring metering lever hight on carburettor 8 897701 02830 Bearing wedge Removing and crankshaft ball bearings 9 897702 30131 Piston pin tool Removing and installing piston pin 10 897603 23030 PTO shaft puller Removing PTO shaft 11 897708 19835 Worm puller Removing auto oiler worm 12 YO89 000010 Worm inserter Installing auto oiler worm 13 897724 01361 Spring pin tool Removing and installing spring pin 4 mm or 5 32 in dia 14 897726 16431 Oil seal tool Installing oil seals 15 897800 79931 Spark tester Checking ignition system 16 897803 30132 Pressure tester Testing carburettor and crankcase leakage 17 897826 16131 Pressure rubber plug Plugging intake port to test crankcase cylinder leakages 18 897827 16131 Pressure plate Plugging intake port to test crankcas
8. H mixture needle anticlockwise and set maximum engine speed at less than 13 000 r min 8 After adjusting carburettor put the limiter cap on the tip of 2 5 mm wood screw and install the caps on L and H mixture needles NOTE Align the limiter caps tabs A with locating slots B in extended housing of carburettor 9 Tap the respective limiter caps in as shown 10 Start engine again and make it sure engine runs at idle speed in the range of 2 300 to 2 800 r min and at WOT engine speed in the range of 11 500 to 13 000 r min Also make it sure chain would not turn at engine idle speed and suitable acceleration NOTE Initial carburettor setting Idle adjust screw L and H mixture needles shown here is to start the engine after restoration or carburettor change Idle adjust screw L and H needles turn for designated engine revolution through procedures indicated here may vary As long as idle and WOT engine speed is set in given range variance would be ignorable CS 4400 1 1 CS 5100 SERVICE INFORMATION CS 5100 2 1 General adjusting rules 1 2 3 4 5 6 Before starting the unit for adjustment check the following items The correct spark plug must be clean and properly gapped The air filter element must be clean and properly installed The muffler exhaust port must be clear of carbon The fuel lines tank vent and fuel filter are in good condition and clear of debris The fuel is fresh
9. e cylinder leakages 19 91007 Compression gauge Measuring cylinder compression CS 4400 9 CS 5100 SERVICE INFORMATION 2 EMISSION ADJUSTMENT GUIDE CS 4400 2 1 General adjusting rules 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 3 The muffler exhaust port must be clear of carbon 4 The fuel lines tank vent and fuel filter are in good condition and clear of debris 5 The fuel is fresh gt 89 octane RON and properly mixed at 50 1 with ISO L EGD 2 stroke oil 6 The recommended bar and chain must be installed to the power head and properly tensioned NOTE Make sure of proper installation of 45 cm guide bar and saw chain when adjusting carburettor or serious engine damage may occur due to overspeeding 2 2 Presetting idle adjust screw L mixture needle and H mixture needle a 1 Turn the L and H mixture needles out _ idle adjust screw anticlockwise to rich side stop and meet limiter caps tabs A with locating slots B 2 Screw 2 5 mm wood screw in the center of the L limiter cap NOTE Screw the wood screw in until it lightly contacts L mixture needle in the cap 3 Pull the wood screw with limiter cap using pliers 4 Repeat Step 2 and Step 3 for H limiter cap by hand 5 Turn Land H mixture needle clockwise
10. n adjust H mixture needle anticlockwise and set maximum engine speed at less than 13 500 r min 8 After adjusting carburettor Press the caps on L and H mixture needles as shown 9 Start engine again and make it sure engine runs at idle speed in the range of 2 300 to 2 800 r min and at WOT engine speed in the range of 12 500 to 13 500 r min Also make it sure chain would not turn at engine idle speed and suitable acceleration NOTE Initial carburettor setting Idle adjust screw L and H mixture needles shown here is to start the engine after restoration or carburettor change Idle adjust screw L and H needles turn for designated engine revolution through procedures indicated here may vary As long as idle and WOT engine speed is set in given range variance would be ignorable
11. re minimum MPa kgf cm psi 0 05 0 5 7 0 Metering lever height mm in 1 65 0 065 lower than diaphragm seat Chain oil discharge volume at 7000 r min mL min U S fl oz min Adjustable 1 5 13 0 05 0 40 Factory set 7 mL min BTDC Before top dead centre With guide bar and saw chain Set idle adjust screw to contact throttle plate before initial setting 4 CS 4400 SERVICE INFORMATION CS 5100 1 3 Torque limits Descriptions Size kgfecm Nem inelbf Starter Starter pawl M 5 70 110 7 11 60 95 system Starter case M4 30 45 3 0 4 5 26 40 Ignition Magneto rotor Flywheel M8 200 240 20 24 175 210 system Ignition coil M4 35 50 3 5 5 0 30 45 Spark plug M14 150 170 15 17 130 150 Fuel Carburettor M5 30 35 3 0 3 5 26 30 syetemn Intake bellows Only CS 5100 M5 30 45 3 0 4 5 26 40 Clutch Clutch hub LM 10 300 400 30 40 260 350 Engine Crankcase M5 t 70 110 7 11 60 95 Engine mount M 5 70 110 7 11 60 95 Muffler M5 70 110 7 11 60 95 Muffler plate M4 15 25 1 5 2 5 13 22 Others Cylinder cover M4 25 45 2 5 4 5 22 40 Cushion Front handle M5 30 45 3 0 4 5 26 40 Oil tank M4 30 40 3 4 26 35 Auto oiler M4 15 25 1 5 2 5 13 22 Throttle latch M4 6 10 0 6 1 0 5 9 Front handle M5 45 65 4 5 6 5 40 55 Brake lever Hand guard M4 25 45 2 5 4 5 22
12. re needle and H mixture needle cccceeseececeeeeeeeeeeens 11 2 3 Adjusting Carburettor ccceeeeeeeeeeeee ees 12 Reference No 01 44C 01 REVISED 200510 ISSUED 200410 2 CS 4400 SERVICE INFORMATION CS 5100 1 SERVICE INFORMATION 1 1 Specifications Model CS 4400 CS 5100 Dimensions Length mm in 398 15 7 Width mm in 252 9 9 Height mm in 272 10 7 Dry weight kg Ib 4 6 10 1 4 9 10 8 Engine Type KIORITZ air cooled two stroke single cylinder Rotation Clockwise as viewed from the output end Displacement cm in 43 5 2 654 49 3 3 008 Bore mm in 43 0 1 693 45 0 1 772 Stroke mm in 30 0 1 181 31 0 1 220 Compression ratio 7 6 1 Carburettor Type Diaphragm horizontal draught with auto return choke Model Walbro WT 416C ZAMA C1Q K79 Venturi size Throttle bore mm in 13 5 15 85 0 532 0 624 13 5 16 0 532 0 630 Ignition Type CDI Capacitor discharge ignition system with electronic timing advancer Spark plug RCJ 6Y Starter Type Automatic rewind Rope diameter x length mm in 3 5 x 1000 0 14 x 39 4 Fuel Type Premixed two stroke fuel Mixture ratio 50 1 2 Petrol Minimum 89 octane petrol RON Two stroke air cooled engine oil ISO L EGD ISO CD13738 JASO FC Tank capacity L U S fl oz 0 6 20 3 Clutch Type Centrifugal 3 shoe slide with 3 tension
13. spring Guide bar Saw chain lubrication type Automatic with volume adjuster Oil Tank capacity L U S fl 0z 0 28 9 5 Sprocket Type Spur Floating rim Number of teeth 7 7 Pitch in 0 325 0 325 Without guide bar and saw chain Cutting devices Guide bar Type CS 4400 45RV58 325 38RV58 325 CS 5100 38RV58 325 45RV58 325 5O0RV58 325 Called length cm 45 50 Gauge in 0 058 Saw chain Number of drive links 64 72 Pitch in 0 325 Gauge in 0 058 CS 4400 CS 5100 SERVICE INFORMATION 1 2 Technical data Model CS 4400 CS 5100 Engine Idling speed r min 2300 2800 2300 2800 Operating speed r min 9500 10500 10500 11000 High speed No load full throttle r min 11500 13000 12500 13500 Clutch engagement speed r min 3500 4000 3500 4000 Compression pressure MPa kgf cm psi 1 05 10 5 146 1 00 10 2 145 Ignition system Spark plug gap mm in 0 6 0 7 0 024 0 028 Minimum secondary voltage 14 5 23 0 CS 4400 at 800 r min CS 5100 at 1500 r min Secondary coil resistance kQ 1 7 2 2 Pole shoe air gaps mm in 0 30 0 40 0 012 0 016 Ignition timing at 800 r min BTDC 14 5 at 1500 r min BTDC 17 at 3000 r min BTDC 18 5 at 10000 r min BTDC 28 Carburettor Idle adjust screw initial setting turns in 1 1 2 2 L mixture needle initial setting turns back 1 1 4 1 1 2 H mixture needle initial setting turns back 3 2 1 4 Test Pressu
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