CS-501SX

ECHO:
CS-501SXH
shindaiwa: 501sx
(Serial number: 37000001 and after)
(Serial number: 38000001 and after)

Copyright C 2019 YAMABIKO Corporation All rights reserved. Ref. No. 401-42
 INTRODUCTION

This service manual contains information for ser-

vice and maintenance of ECHO CHAIN SAW,
model CS-501SX,CS-501SXH, shindaiwa
CHAIN SAW, model 501sx.
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. We recommend you make use of
Operator’s Manual and Parts Catalogue together
with this manual when servicing.
We are constantly working on technical improve-
ment of our products. For this reason, technical
data, equipment and design are subject to
change without notice. All specifications, illustra-
tions and directions in this manual are based on
the latest product information available at the
time of publication.

NOTE: This service manual contains pictures

with different model name for other markets and
different colored model.
CS-501SX, CS-501SXH
501sx TABLE OF CONTENTS 1
Page Page
1 SERVICE INFORMATION .....................................2 5 CLUTCH SYSTEM ..............................................36
1-1 Specifications ...................................................2 5-1 Inspectng clutch parts ....................................37
1-2 Technical data ..................................................3 5-2 Replacing clutch parts ....................................38
1-3 Torque limits .....................................................4 5-3 Installing clutch assembly...............................38
1-4 Special repairing materials ...............................4
1-5 Service Limits ...................................................5 6 CHAIN BRAKE SYSTEM....................................40
1-6 Special tools .....................................................6 6-1 Disassembling chain brake ............................41
6-2 Assembling brake parts ..................................42
2 STARTER SYSTEM ..............................................7
2-1 Disassembling starter assembly.......................8 7 SAW CHAIN LUBRICATION SYSTEM...............43
2-2 Replacing starter rope ......................................9 7-1 Inspecting oil cap and strainer........................44
2-3 Assembling starter..........................................10 7-2 Inspecting auto-oiler assembly and oil line.....45
2-4 Replacing starter pawl ....................................12 7-3 Inspecting oil tank vent ...................................46

3 IGNITION SYSTEM .............................................13 8 ENGINE ...............................................................47

3-1 Troubleshooting guide ....................................14 8-1 Testing cylinder compression .........................48
3-2 Testing spark ..................................................15 8-2 Cleaning cooling air passages .......................48
3-3 Inspecting spark plug .....................................15 8-3 Inspecting muffler and exhaust port ...............49
3-4 Inspecting ignition switch................................16 8-4 Testing crankcase and cylinder seal...............50
3-5 Replacing ignition switch ................................16 8-5 Inspecting cylinder..........................................51
3-6 Inspecting ignition coil resistance ...................17 8-6 Inspecting piston and piston ring ....................52
3-7 Replacing spark plug cap and coil..................18 8-7 Replacing oil seal ...........................................53
3-8 Replacing ignition coil.....................................18 8-8 Disassembling crankcase...............................54
3-9 Setting pole shoe air gaps ..............................19 8-9 Replacing ball bearing and oil seal.................54
3-10 Inspecting flywheel and key ...........................19 8-10 Assembling crankshaft and crankcase ...........55
8-11 Installing piston...............................................56
4 FUEL SYSTEM ...................................................21 8-12 Installing piston ring and cylinder ...................57
4-1 Inspecting air filter ..........................................22
4-2 Inspecting fuel cap and fuel strainer...............22 9 REAR HANDLE AND CONTROL SYSTEM .......58
4-3 Inspecting fuel tank and line ...........................23 9-1 Replacing cushions ........................................59
4-4 Inspecting and replacing tank vent .................24 9-2 Replacing throttle trigger ................................61
4-5-1 Replacing fuel line ..........................................26 9-3 Service hint for heated handle (CS-501SXH only) ...63
4-5-2 Replacing fuel vent pipe .................................27 9-3-1 Inspecting heated handle ...............................64
4-6 Adjusting carburetor .......................................28 9-3-2 Replacing stator assembly .............................66
4-6-1 General adjustment rules ...............................28 9-3-3 Replacing rear handle heater .........................67
4-6-2 Initial setting Throttle adjust screw, L mixture 9-3-4 Replacing heater switch .................................69
needle and H mixture needle .........................28
4-6-3 Adjusting carburetor .......................................29 10 GUIDE BAR MOUNTING SYSTEM ..................70
4-7 Air shutter .......................................................30 10-1 Replacing chain tensioner ..............................71
4-8 Testing carburetor...........................................31 10-2 Replacing guide bar stud................................71
4-9 Inspecting crankcase pulse passage .............32 10-3 Installing guide bar stud .................................72
4-10 Inspecting metering lever height ....................32
4-11 Inspecting inlet needle valve ..........................33 11 MAINTENANCE GUIDE ....................................73
4-12 Inspecting diaphragm .....................................33 11-1 Disassembly Chart .........................................73
4-13 Replacing Welch plug.....................................34 11-2 Troubleshooting guide ....................................74
4-14 Installing carburetor ........................................35 11-3 Service Intervals .............................................76
 CS-501SX, CS-501SXH
2 SERVICE INFORMATION 501sx

1 SERVICE INFORMATION

1-1 Specifications
Models CS-501SX, 501sx CS-501SXH
Dimensions Length* mm(in) 395 (15.6)
Width mm(in) 235 (9.3)
Height mm(in) 290 (11.4)
Dry weight* kg(lb) 4.7 (0.2) 4.9 (10.8)
Engine Type YAMABIKO, air-cooled, two-stroke, single cylinder
Rotation Clockwise as viewed from the output end
3 3
Displacement cm (in ) 50.2 (3.063)
Bore mm(in) 44.0 (1.732)
Stroke mm(in) 33.0 (1.299)
Compression ratio 7.2
Carburetor Type Diaphragm horizontal-draft
Model Walbro WT-1139
Venturi size-Throttle bore mm(in) 13.5 - 15.85 (0.531 - 0.624)
Ignition Type CDI (Capacitor discharge ignition) system
Spark plug NGK BPMR8Y
Exhaust Muffler type Spark arrester muffler
Starter Type Automatic Rewind
Rope diameter x length mm(in) 3.8 x 910 (0.15 x 35.8)
Fuel Type** Mixed two-stroke fuel
Mixture ratio 50 : 1 (2 %)
Gasoline Minimum 89 octane petrol
Two-stroke air cooled engine oil ISO-L-EGD (ISO/CD13738), JASO FC/FD
Tank capacity L ([Link].) 0.5 (16.9)
Clutch Type Centrifugal type
Guide bar / Saw chain lubrication type Automatic with volume adjuster
Oil Tank capacity L ([Link].) 0.28 (9.5)
Auto oiler Type Clutch driven type
Sprocket Type Floating rim
Number of teeth 7
Pitch in 0.325
Heated handle --- Equipped
* Without guide bar and saw chain.
** Premixed alkylate fuel for 2-stroke can be used.

Cutting devices
Guide bar Type V40R21-68AA V45R21-72AA V50R21-80AA
Called length cm 40 45 50
Gauge in 0.058
Saw chain Type Oregon 21BPX, Carlton K2L
Number of drive links 68 72 80
Pitch in 0.325
Gauge in 0.058
CS-501SX, CS-501SXH
501sx SERVICE INFORMATION 3
1-2 Technical data
Models CS-501SX, 501sx CS-501SXH
Engine
Compression pressure MPa (kgf/cm2) (psi) 0.95 (9.7) (138)
Clutch engagement speed r/min 3,900
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 mm(in) 6.0 (0.24)
Secondary coil resistance kΩ 2.5 - 2.9
Pole shoe air gaps mm(in) 0.3 - 0.4 (0.012 - 0.016)
Ignition timing at 3,000 r/min °BTDC 20 19
at 8,000 r/min °BTDC 32 30
at 10,000 r/min °BTDC 34 34
Carburetor
Test Pressure, minimum MPa (kgf/cm2) (psi) 0.05 (0.5) (7.0)
Metering lever height mm(in) 1.65 (0.06) lower than diaphragm seat
Tool to adjust mixture needles D-shaped tool (L) P/N X645-000031
(Carb. adjustment tool P/N Y089-000094)
Carburetor adjustment
Before carburetor adjustment : --- Turn off heater switch.
1) Initial setting H mixture needle turn out 3 5/8
L mixture needle turn out 1 3/4
1
Throttle adjust screw turn in* 2 1/8
Engine warm-up Idle - WOT : Total 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 3,500
4) Set idle speed
r/min 2,700
by turning L mixture needle CCW
5) Confirm H mixture needle position Turn H mixture needle CCW to confirm engine speed
before WOT setting decreases less than or equal to 12,500 r/min.
6) WOT setting r/min Turn H mixture needle CW in 1/8 turn increments
with the engine at idle, then accelerate to WOT and
check engine [Link] final engine speed should
fall within: 13,000 - 13,800
7) Verify final engine speed with standard equipment Idle: 2,300 - 3,100
r/min WOT: 13,000 - 13,800
8) Verify clutch engagement speed Confi rm clutch engagement speed.
If it is less than 1.25 times the idle speed, adjust
the idle speed by turning TAS CCW.
Chain oil discharge volume at 7,000 r/min Ajustable: 3.0 - 16.5 (0.12 - 0.65)
mL/min ([Link]./min) (Factory set: 7 mL/min)
BTDC: Before top dead center WOT: Wide open throttle CCW: Counterclockwise TAS: Throttle adjust screw
*1 Set Throttle adjust screw to the point that its tip just contacts throttle plate before initial setting.
*2 If chain starts to rotate during adjustment process step 2), decrease engine speed by turning TAS CCW
until chain stops and then redo step 2). Repeat this until chain no longer rotates after the adjustment step 2).
 CS-501SX, CS-501SXH
4 SERVICE INFORMATION 501sx

1-3 Torque limits

Descriptions Size kgf•cm N•m in•lbf
Starter system Starter pawl M5 90 - 120 9- 12 80 - 105
Starter case M4 20 - 30 2- 3 18 - 25
Ignition system Magneto rotor (Flywheel) M8 150 - 170 15 - 17 130 - 150
Ignition coil M4 30 45 3 4.5 25 40
Igniton switch M10 20 - 30 2 - 3 18 - 25
Spark plug M14 130 - 170 13 - 17 113 - 150
Fuel system Carburetor M5 20 - 30 2 - 3 18 - 25
Carburetor elbow M4 20 - 30 2 - 3 18 - 25
Clutch Clutch shoe LM10 280 - 300 28 - 30 245 - 265
Clutch drum M8 150 - 170 15 - 17 130 - 150
Engine Crankcase M5 70 - 90 7 - 9 60 - 80
Muffler M5 70 - 90 7 - 9 60 - 80
Cylinder M5 70 - 90 7 - 9 60 - 80
Cylinder cover M4 25 - 35 2.5 - 3.5 22 - 30
Others Auto-oiler M4 20 - 35 2 - 3.5 18 - 30
Oiler cover M4 30 - 45 3 - 4.5 25 - 40
Crankcase (at oil tank) M5 50 - 70 5 - 7 45 - 60
Cushion (on Front handle) M5 20 - 30 2 - 3 18 - 25
Front handle M5 40 - 55 4 - 5.5 35 - 48
M4 30 - 45 3 - 4.5 25 - 40
Rear handle (M side) M5 40 - 55 4 - 5.5 35 - 48
assembly (D side) M5 40 - 55 4 - 5.5 35 - 48
Handle grip M4 20 - 30 2 - 3 18 - 25
Brake lever (D side) M5 40 - 60 4 - 6 35 - 40
(M side) M5 50 - 70 5 - 7 45 - 60
Brake cover M4 10 - 20 1 - 2 9 - 18
Washer (at brake band) M4 15 - 25 1.5 - 2.5 13 - 22
Sprocket guard plate M4 10 - 15 1 - 1.5 9 - 13
Guide bar nut M8 200 - 230 20 - 23 175 - 200
Chain catcher M5 50 - 70 5 - 7 45 - 60
Spike M5 50 - 70 5 - 7 45 - 60
Regular bolt, nut, and screw M3 6 - 10 0.6 - 1 5 - 9
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

1-4 Special repairing materials

Material Location Remarks
Adhesive Cushion Loctite #406 (424) or equivalent
Grease Auto-oiler worm
Clutch needle bearing
Choke knob
Oil seal inner lips EPNOC AP2 (Lithium based grease)
P/N X695-000060
Chain brake (metal contact part)
Throttle rod
Bevel gear, Screw, Chain tensioner
CS-501SX, CS-501SXH
501sx SERVICE INFORMATION 5
1-5 Service Limits

A B C D

5K177 5K083 5K084 5K081

E F G H

5K082 5K016 5K025 5K178

K L M P

5K173 5K174 5K190 5K097

Description mm (in)
A Cylinder bore When plating is worn and aluminium can be seen
B Piston outer diameter Min. 43. 87 (1.727)
C Piston pin bore Max. 11. 025 (0.4341)
D Piston ring groove Max. 1. 6 (0.063)
E Piston ring side clearance Max. 0. 1 (0.004)
F Piston pin outer diameter Min. 10. 98 (0.4323)
G Piston ring width Min. 1. 45 (0.057)
H Piston ring end gap Max. 0. 8 (0.03)
K Con-rod small end bore Max. 15. 025 (0.5915)
L Crankshaft runout Max. 0. 02 (0.001)
M Sprocket bore Max. 12. 75 (0.5020)
N Clutch drum bore Max. 73. 5 (2.89)
P Sprocket wear limit Max. 0. 5 (0.02)
 CS-501SX, CS-501SXH
6 SERVICE INFORMATION 501sx

1-6 Special tools

1 2 3 4 5

Made in Germany
T27x200
8 6 9 7 4 5
0 1 0 5 5 7
MOLYBDEUM VANADIUM
5.0X160

4
6 7 8 9 10

e
00 m ug
91 5m a
3 G
P = ap
4 G
01 ir

4
#. A

/N .
n
tio
ni
Ig

11 12 13 14 15

5 1.3
1.6 5

0.4 1.5
4 3

2
6

1
7 0

16 17 18 19 20 22

21 23

Key Part Number Description Reference

1 897802-33330 Tachometer PET-1000R Measuring engine speed to adjust carburetor
2 897559-02831 T-hex. wrench (4 mm) Removing and installing hex. socket bolt (M5)
3 X602-000230 T-hex. wrench (5 mm) Removing and installing hex. socket bolt (M6)
4 X602-000340 Torx wrench (T27) Removing and installing torx bolt
5 Y089-000111 Puller Removing magneto rotor (flywheel) and crankcase
6 X640-000370 Clutch spanner Removing and installing clutch assembly
7 91004 Module air gap gauge Adjusting pole shoe air gaps
8 91037 Compression gauge Measuring cylinder compression
9 897702-30131 Piston pin tool Removing and installing piston pin
10 897701-02830 Bearing wedge Removing ball bearings on crankshaft
11 897563-19830 Metering lever gauge Measuring metering lever height on carburetor
12 X646-000360 Oil seal tool Installing oil seals and clutch plate
13 897800-79931 Spark tester Checking ignition system
14 897803-30133 Pressure tester Testing carburetor and crankcase leakage
15 Y089-000094 Carburetor adjustment tool Adjusting caburettor
16 500-500 Welch plug tool (Walbro) Removing and installing welch plug
17 X646-000150 Collar oil seal tool Set oil seal collect position
18 91149 Pressure / vacuum tester Testing crankcase / cylinder leakages
19 91041 Pressure rubber plug Plugging exhaust port to test crankcase/cylinder leakages
20 897826-16131 Pressure rubber plug Plugging intake port to test crankcase/cylinder leakages
21 897827-16131 Pressure plate Plugging intake port to test crankcase/cylinder leakages
22 101115-37531 Plug Testing crankcase / cylinder leakages
23 900720-00009 O-ring Testing crankcase / cylinder leakages
CS-501SX, CS-501SXH
501sx STARTER SYSTEM 7
2 STARTER SYSTEM

(A) Starter case (G) Starter rope

(B) Rope guide (H) Fan cover
(C) Starter grip (J) Starter pawl
(D) Rewind spring (K) Flywheel
(E) Rewind spring case (L) Needle grommet
(F) Rope reel

(G)

(C)

(F) (K)

(J)
(B)

(E) (H)

(D)

(L)

(A)
 CS-501SX, CS-501SXH
8 STARTER SYSTEM 501sx

2-1 Disassembling starter assembly

1. Remove four screws and remove starter assem-

bly (A) from unit.

2. Pull out starter rope about 30 cm (12 in) and

hold rope reel (B) by hand. Loop excess rope in
rope reel notch (b) as shown.

3. Rotate rope reel (B) counterclockwise to release

tension of rewind spring.
B

4. Remove bolt (C).

5. Remove rope reel (B) and rewind spring case (D)

with rewind spring.

6. Carefully remove rewind spring and case (D)

as one piece. Rewind spring is under tension and
may release unexpectedly.

C
WARNING DANGER
Wear eye protection and take care when
D removing starter drum. Rewind spring may
B unwind suddenly and cause personal injury.
CS-501SX, CS-501SXH
501sx STARTER SYSTEM 9
2-2 Replacing starter rope

1. Pull out and untie knot (A).

2. Pull knot (B) to remove rope from rope reel (C).

3. When installing a new starter rope, singe both

ends of the rope to prevent fraying.

4K287
4. Make a knot (D) at end of starter rope and pass
the rope through hole of rope reel, then press the
knot (D) into recess as shown.

5. Pass the other end of starter rope through

rope guide on starter case, then pass starter rope
through starter grip and make a knot as shown.

6. Tighten knot. Push knot into recess of starter

grip.
 CS-501SX, CS-501SXH
10 STARTER SYSTEM 501sx

2-3 Assembling starter

1. If rewind spring (A) is removed from spring case

(B), rewind inside case as shown.

2. Carefully install rewind spring and case (B) on

c1 starter case (C) as one piece. Match ear (b) and
C with ear (c1) on starter case.

d 3. Assemble rope reel (D) engaging hook (d) with

hook (a) of rewind spring.

NOTE: Apply lithium based grease, ECHO XTend-

ed Protection Lubricant or Red Armor Lubricant on
around startet shaft (c2) of starter case (C) if dry.
D a
c2
4. Check for proper engagement of rewind spring
and rope reel by turning rope reel (D) clockwise
and counterclockwise.

D
CS-501SX, CS-501SXH
501sx STARTER SYSTEM 11
2-3 Assembling starter (continued)

5. Reinstall bolt (E) on starter post.

6. Pull out starter rope inside starter case. Rotate

rope reel clockwise several turns with starter rope
hooked at notch (F) as shown. Hold rope reel to
E
prevent it from unwinding and pull out starter grip
to take the rope slack.

7. Pull starter several times to check rewind spring

tension. If starter is not rewinding fully, increase
spring tension by rotating rope reel one more turn
clockwise following above step (6).

8. Pull out starter rope all the way, and check that
rope reel can be rotated an additional half or more
turn clockwise as shown, to prevent rewind spring
from breaking.

9. If rope reel can not be turned clockwise, reduce

tension by rotating rope reel counterclockwise one
turn with starter rope hooked at notch (F).
 CS-501SX, CS-501SXH
12 STARTER SYSTEM 501sx

2-4 Replacing starter pawl

1. Remove starter assembly from unit.

A 2. Loosen bolt (A) and remove washer, pawl (B),
spacer (C) and torsion spring (D). Replace dam-
aged or worn parts.

NOTE: When it is hard to loosen bolt, install clean

B rope (E) in spark plug hole to stop crankshaft rota-
tion and remove bolt easily.

C
E
D

3. Install torsion spring, spacer, pawl, washer and

bolt. To avoid pinching of torsion spring, install
these parts without setting the end (F) of torsion
spring on starter pawl. The bolt is pre-coated with
sealant on the thread. If the sealant is peeled off,
apply thread locking sealant (Loctite #242, Three-
Bond #1324 or equivalent).
F

4. Using fine wire (G) or appropriate tool, place the

G end (F) of torsion spring on pawl (B), by hooking
F and passing under pawl as shown. Remove fine
wire or tool.

5. Make sure pawl can move smoothly. If it does

not move smoothly, check parts for correct installa-
tion.

B
CS-501SX, CS-501SXH
501sx IGNITION SYSTEM 13
3 IGNITION SYSTEM

(A) Flywheel (E) Spark plug cap

(B) Ignition coil (F) Switch lead
(C) Spark plug (G) Ignition switch
(D) Spark plug cap coil

(E)

(D)

(C)

(G)

(A)

(F)

(B)
 CS-501SX, CS-501SXH
14 IGNITION SYSTEM 501sx

3-1 Troubleshooting guide

Start
Inspect Remedy

OK
S.T.

Not Not Adjust pole shoe air gaps.

OK Pole OK (Inspect flywheel magnet
shoe air
Not gaps at the same time. Go to
OK Clean / OK A if OK.)
Spark plug Regap / S.T. OK
Replace.
Not Not
OK OK
Flywheel OK
magnet Replace flywheel.
Not
Spark OK OK OK
plug cap/ Replace. S.T. A
coil
Not OK OK
OK OK S.T. R.T.
Not Not
OK OK
Not
Ignition OK OK
Replace. S.T.
switch
Not Not
OK OK OK OK
Flywheel Replace. R.T.*
key

Not OK
Secondary Replace
coil OK OK
resist- ignition S.T.
ances coil.
Not
OK OK

Not
OK
Not
Leads OK Repair / OK Replace ignition coil and / or inspect other
connections Replace. S.T. systems.
Not
OK OK S.T.: Spark test. End
R.T.: Running test including actual cutting.
CS-501SX, CS-501SXH
501sx IGNITION SYSTEM 15
3-2 Testing spark

1. Remove cleaner lid, air filter and cylinder cover.

a2 Remove spark plug cap from spark plug.
B 2. Connect Spark tester 897800-79931 (A) to high
tension lead and connect tester lead (B) on spark
plug.

3. Screw in adjuster (a1) until the needle tips con-

tact. Turn out adjuster (a1) 4 turns to set spark
tester gap (a2) to 4 mm (0.16 in).

4. Turn ignition switch to “I” position. Pull starter

A grip several times.

5. If spark is steady blue or white at the tester gap,

a1 ignition system is considered good. Go to inspect-
ing spark plug.

6. If no spark exists or spark is intermittent in

yellow, orange, or red, continue with further inspec-
tion.

DANGER
*Do not test near spark plug hole without
spark plug installed, otherwise there is a
chance to ignite fuel mixture inside cylinder.
GA
SO
*Do not touch metal parts of spark tester
LIN
E while performing the test to avoid receiving
electrical shock.
*Do not check spark in area where gasoline
is spilled or flammable gases may exist.

3-3 Inspecting spark plug

1. Remove spark plug to inspect for spark plug gap

fouling, cracked or broken insulator, cracked outer
A electrode, or rounded center electrode. Replace
spark plug as required.

Spark plug gap (A) standard

: 0.6 to 0.7 mm (0.024 to 0.028 in)

2. If engine does not start with correct spark plug,

inspect if spark plug is wet or dry. If it is exces-
sively wet or dry, inspect fuel system.
 CS-501SX, CS-501SXH
16 IGNITION SYSTEM 501sx

3-4 Inspecting ignition switch

1. Remove cleaner lid, air filter and cylinder cover.

2. Remove switch lead (A) from ignition coil.

3. Connect one probe of Ohm-meter or multi-meter

to switch lead. Connect the other probe to cylinder
fin (B).

4. When ignition switch is in “I” position, tester

should indicate infinite resistance.

5. When ignition switch is in “O (STOP)” position,

tester should show that the circuit is in conducting
state (closed circuit).

6. If ignition switch is defective, replace with a new

one.

3-5 Replacing ignition switch

1. Remove cleaner lid, air filter and cylinder cover.

E A 2. Remove bolts (A), washers (B) and bolts (C).

3. Remove carburetor elbow (D) and carburetor (E).

B
B

D C

4. Loosen nut (F), and remove ignition switch (G)

with switch lead (H) from the unit.
G
H

F 5. Assemble new ignition switch with switch lead

on the unit. Fasten nut (F) on ignition switch.
CS-501SX, CS-501SXH
501sx IGNITION SYSTEM 17
3-6 Inspecting ignition coil resistance

1. Remove cleaner lid, air filter and cylinder cover.

2. Connect one probe of Ohm-meter or multimeter

to spark plug cap coil (A).

3. Connect the other probe to cylinder fin (B) to

measure secondary coil resistance. Secondary
coil resistance should be in the range of 2.5 to 2.9
kΩ.

4. I f t h e m e t e r r e a d i n g i n d i c a t e s i n fi n i t e
resistance, remove spark plug cap and spark
plug cap coil, and measure resistance between the
conduction wire of high tension lead and ignition
coil core.

5. If the reading at step 2 or 3 is not in the range of

A 2.5 to 2.9 kΩ, replace with a new ignition coil (Go
to “3-8 Replacing ignition coil”).

B
 CS-501SX, CS-501SXH
18 IGNITION SYSTEM 501sx

3-7 Replacing spark plug cap and coil

1. Disconnect spark plug cap (A) from spark plug.

Remove cap cover from spark plug cap.

2. Apply some oil in spark plug cap (A) for easy re-
moval from high tension lead (B).
B
3. Pull spark plug cap away from high tension lead.

4. Inspect spark plug cap coil (C) for corrosion

and correct connection. Inspect spark plug cap for
cracks. Replace as required.
A
NOTE: Make sure spark plug cap coil (C) contacts
center core of high tension lead when reinstalling
it.

5. Coat end of high tension lead (B) with small

amount of oil, and insert it into spark plug cap (A)
as shown, until the spark plug cap coil is properly
C seated in the cap.

Coat with small amount of oil

3-8 Replacing ignition coil

1. Remove cleaner lid. Disconnect spark plug cap

from spark plug. Remove cylinder cover.

2. Remove starter assembly and fan cover refer-

ring to “2-1 Disassembling starter assembly“.

3. Disconnect switch lead (A) from ignition coil.

Loosen bolts (B) of ignition coil.

4. Remove ignition coil from cylinder.

5. Remove spark plug cap and spark plug cap coil

B
from high tension lead (Refer to “3-7 Replacing
A spark plug cap and coil”).

6. Install spark plug cap and spark plug cap coil,

switch lead (A) to new ignition coil.

7. Loosely install new ignition coil with two bolts

(B). Set air gap (Refer to “3-9 Setting pole shoe air
gaps“). Tighten two bolts (B). Reinstall fan cover,
starter assembly and cylinder cover.

8. Connect spark plug cap to spark plug. Reinstall

cleaner lid.
CS-501SX, CS-501SXH
501sx IGNITION SYSTEM 19
3-9 Setting pole shoe air gaps

1. Insert Module air gap gauge: 91004 (A) or 0.3

- 0.4 mm (0.012 - 0.016 in) thick feeler gauge be-
tween flywheel and ignition coil shoes.

2. Rotate flywheel until magnetic poles of flywheel

face ignition coil shoes.

3. Hold ignition coil against flywheel and tighten

the bolts to specified torque (Refer to “Service in-
formation 1-3 Torque limits”). After tightening bolts,
A remove Module air gap gauge: 91004 (A) (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.

3-10 Inspecting flywheel and key

1. Inspect magnetic force of flywheel using flux

meter, or bridging with flat head screwdriver as
shown.

2. If magnetic force is weak, replace flywheel as

follows.

3. Install piston stopper X644-000020 (A) or clean

rope into spark plug hole by hand, to stop crank-
shaft rotation.

NOTE: Do not use power tool to remove nut (B).

Otherwise, piston damage may occur.

4. Remove nut (B) by rotating counterclockwise.

A
 CS-501SX, CS-501SXH
20 IGNITION SYSTEM 501sx

3-10 Inspecting flywheel and key (continued)

5. Remove starter pawls. Then set Puller Y089-

C 000111 (C) on flywheel as shown.

6. Tighten two nuts on the puller alternately to re-

move flywheel.

7. Inspect woodruff key for damage or shearing.

Replace as required.

8. Wipe off oil from taper part of crankshaft before

assembling flywheel.

9. Install woodruff key into key groove.

10. Reinstall starter pawls (Refer to “2-4 Replacing

starter pawl”).

11. Align flywheel key groove with woodruff key on

crankshaft. Install flywheel and fasten flywheel nut
clockwise.
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 21
4 FUEL SYSTEM

( A ) Fuel cap (M)

( B ) O-ring
( C ) Fuel tank vent
( D ) Fuel tank (L)
( E ) Fuel strainer
( F ) Fuel line
( G ) Pulse line
( H ) Carburetor
(H)
( J ) Carburetor elbow
( K ) Gasket
( L ) Air filter
( M ) Cleaner lid (K)

(J)
(G)
(F)

(E)

(C)

(D)

(A) (B)
 CS-501SX, CS-501SXH
22 FUEL SYSTEM 501sx

4-1 Inspecting air filter

1. Close choke shutter. Remove cleaner lid and air

filter.
A 2. Inspect air filter (A). If blocked with dirt or dust,
remove the obstruction with using brush.

2. If heavily blocked with dirt or dust, clean air filter

(A) with compressed air or wash away with non-
inflammable solvent/detergent.

WARNING DANGER
Wear eye protection when working with
compressed air. Eye damage can occur from
flying particles.

4-2 Inspecting fuel cap and fuel strainer

1. Remove fuel cap.

B
2. Inspect fuel cap for cracks and O-ring (A) for
cuts or damage, and replace with new one as re-
quired.

A 3. Replace fuel cap (B) if damaged.

4. Pull fuel strainer (C) from fuel tank using a wire

hook (D). Clean fuel strainer. Replace if defective
or heavily soiled.

5. Reinstall fuel cap.

C
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 23
4-3 Inspecting fuel tank and line

1. Clean fuel tank inside as required.

2. Remove cleaner lid, air filter and cylinder cover.

3. Disconnect fuel line (A) from carburetor.

4. Connect Pressure tester 897803-30133 (B) to

fuel line.
C
D NOTE: To connect pressure tester to fuel line, it is
recommended to use pipe joint V186-000020 (C).
B
5. Remove fuel cap and pull out fuel strainer from
fuel tank.

6. Pinch fuel line (D) with longnose pliers as

shown.

NOTE: Wrap the ends of longnose pliers with tape

(or cover with soft pipes) to protect fuel line from
damage.

7. Apply pressure approx. 49 kPa (0.5 kgf/cm2) (7

psi).

C 8. If pressure drops, replace fuel line.

9. Put fuel strainer in fuel tank and fasten fuel cap

securely.

10. Apply pressure approx. 9.8kPa (0.1 kgf/cm2)

(1.4 psi).

11. Pressure should not drop. If pressure drops,

leakage may occur from fuel cap, fuel cap O-ring,
mating surface of fuel tank on rear handle, grom-
met, or tank vent. Inspect and replace defective
part(s) with new one.

12. Remove pressure tester and connect fuel line

to carburetor.
 CS-501SX, CS-501SXH
24 FUEL SYSTEM 501sx

4-4 Inspecting and replacing tank vent

NOTE: Tank vent prevents a vacuum from forming

in fuel tank when fuel in fuel tank is being con-
sumed. When pressure in fuel tank becomes too
high, tank vent releases the pressure.

A
1. Remove cleaner lid, air filter and cylinder cover.
Remove tank vent (A) from fuel tank (Refer to “9-1
Replacing cushions”) and connect Pressure / vac-
uum tester 91149 (B).

B
2. Apply pressure approx. 49 kPa (0.5 kgf/cm2) (7
psi). Make sure pressure is stable in range of 9.8 -
39.2 kPa (0.1 - 0.4 kgf/cm2) (1.4 - 5.7 psi).

3. If it is not in the range, gently clean tank vent

with compressed air or replace with new one.
A
NOTE: Do not disassemble valve in tank vent as-
sembly. Damage to valve will occur.

4. Apply negative pressure 19.6 kPa (0.2 kgf/cm2) (3

psi).

5. Tank vent should pass air freely without holding

any pressure. If it does not, replace tank vent with
new one.
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 25
4-4 Inspecting and replacing tank vent (continued)

NOTE: Inspection using 897803-30133

If Pressure / vacuum tester 91149 is not available,
tank vent can be inspected with Pressure tester
897803-30133 as follows.
A
1. Connect tank vent (A) to Pressure tester
897803-30133 (B).
B
2. Apply pressure approx. 49 kPa (0.5 kgf/cm2) (7
psi), make sure pressure is stable in range of 9.8 -
39.2 kPa (0.1 - 0.4 kgf/cm2) (1.4 - 5.7 psi).

3. If it is not in the range, gently clean tank vent

with compressed air or replace with new one.

NOTE: Do not disassemble valve in tank vent as-

sembly as shown. Damage to valve will occur.

valve

4. Remove cap (C) of tank vent, and clean sponge

C (D).
D
5. Cut pipe 363011-00210 (E: 7x11x170mm) and
382011-01110 (F: 9x13x350) in approx. 30mm (1
1/4 in) length, and connect them to pressure tester
as shown. Connect tank vent (A) without cap to
E pipe as shown.

F 6. Plug hole (a) with finger and apply pressure 19.6

kPa (0.2 kgf/cm2) (3 psi). The pressure should hold
A steady.

7. Remove finger from hole (a). Tank vent should

pass air freely without holding any pressure. If it
does not, replace tank vent with new one.

a
 CS-501SX, CS-501SXH
26 FUEL SYSTEM 501sx

4-5-1 Replacing fuel line

1. Remove cleaner lid, air filter and cylinder cover.

2. Disconnect fuel line (A) and pulse line (B) from

B carburetor.

3. Remove carburetor by disconnecting throttle rod

(C) and choke knob (D).
A

C
D

4. Remove crankcase assembly (Refer to “9-1

Replacing cushions”).

5. Remove fuel cap, and remove fuel strainer (E)

A and clip (F) from fuel line (A).

h F 6. Pull out fuel line (A) in direction of arrows. Re-

place them if defective.

G 7. Set clip (F) on new fuel line (A) and connect fuel
strainer (E).
E
8. Insert shorter side (a1) of new fuel line (A)
through fuel tank (G). Pull out fuel line (A) through
hole (h) in direction of arrows.
A

a1: 78 mm
9. Reinstall crankcase assembly (Refer to “9-1
Replacing cushions”), carburetor (Refer to “4-14
Installing carburetor”), cleaner case, air filter and
F a2: 90 mm cleaner lid.

E
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 27
4-5-2 Replacing fuel vent pipe

1. Remove fuel tank vent (A) with pipe (B) from

rear handle assembly (C).
A

C
B

2. Disconnect pipe (B) from fuel tank vent (A).

Replace them if defective (Refer to “4-4 Inspecting
and replacing tank vent”).

3. Connect pipe (B) to fuel tank vent (A).

A
B

4. Insert pipe (b) to hole (c1) on rear handle as-

sembly (C). Pass pipe (B) through notch (c2) on
A rear handle assembly (C).

5. Reinstall crankcase assembly (Refer to “9-1

Replacing cushions”), carburetor (Refer to “4-14
Installing carburetor”), cleaner case, air filter and
cleaner lid.

c2 c1
C
B
 CS-501SX, CS-501SXH
28 FUEL SYSTEM 501sx

4-6 Adjusting carburetor

4-6-1 General adjusting rules

A. Before adjustment, check the following items.

1. The correct spark plug must be clean and properly gapped.

2. The air 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 ( > 89 octane : RON ) and properly mixed at 50 : 1 with “ISO L-EGD” or “JASO FC/
FD” 2-stroke oil.

6. 40, 45 or 50 cm bar and chain must be installed, and properly tensioned.

7. For CS-501SXH, turn off the heater switch.

B. Preliminary adjustment. Adjustment by Throttle adjust screw of carburetor.

Start and run engine for 100 seconds alternating engine speed between WOT and idle every 5 seconds.
Adjust throttle adjust screw to 2,700 +/- 200 r/min. Make sure WOT engine speed in range 13,000 -
13,800 r/min. If engine does not run correctly after this adjustment, proceed to the next step 2-2.

4-6-2 Initial setting Throttle adjust screw, L mixture needle and H mixture needle

Tools Required: Small flat head screwdriver with 2.5

mm blade, P/N 897802-33330 tachometer PET-
1000R, P/N Y089-000094 Carburetor adjustment
(D) tool (A).

1. Turn L and H mixture needles clockwise until

lightly seated, and then turn out both mixture nee-
(B) (C)
dles following turns:

L mixture needle (B) : 1 3/4

H mixture needle (C) : 3 5/8

NOTE: If needles are overtighted during seating,

damage to carburetor may occur.

2. Remove air cleaner lid and air filter to expose

the Throttle adjust screw and throttle plate. Turn
Throttle adjust screw (D) counterclockwise until
Throttle adjust screw tip just touches throttle plate.
2
(A) Then turn Throttle adjust screw (D) 2 1/8 turns
3

clockwise. Reinstall air filter, and cleaner lid.

1
4

7
NOTE : The initial carburetor settings for Throttle
adjust screw, L and H mixture needles are intended
to start and run the engine before final carburetor
adjustments are made through this procedure.
The actual number of turns needed for engine
operation may vary.
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 29
4-6-3 Adjusting carburetor
1. Start and warm engine for 100 seconds al-
ternating engine speed between WOT and idle
every 5 seconds. Turn H mixture needle (C) coun-
terclockwise until engine speed drops to approx.
12,500 r/min at WOT.
(D)
(B) (C) NOTE : Do not run engine at high speed without
load longer than 10 seconds, or engine damage
may occur.
2. Adjust L mixture needle (B) using Carbure-
tor adjustment tool (A) to reach maximum engine
speed just before lean drop off.
If chain starts to rotate during adjustment,
decrease engine speed by turning throttle adjust
screw (D) counterclockwise untill chain stops and
then readjust L mixture needle (B).

3. Set idle speed to 3,500 r/min by turning Throttle adjust screw (D). Engine speed should be stable at 3,500
+/- 50 r/min after Throttle adjust screw adjustment.

4. Turn L mixture needle (B) counterclockwise reducing engine idle speed 800 r/min to set idle speed at
2,700 r/min. The engine idle speed ranges is 2,600 - 2,800 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. Before adjustment, WOT engine speed should be 12,500 r/min or less. If engine speed is higher, turn
H mixture needle (C) counterclockwise until 12,500 r/min is achieved. To make the final WOT engine
speed adjustment, turn H mixture needle (C) clockwise in 1/8 turn increments with the engine at idle, then
squeeze throttle trigger and check WOT engine speed. The final WOT engine speed should fall within
13,000 - 13,800 r/min.

6. Start engine, and verify engine idle speed ranges from 2,300 to 3,100 r/min, and WOT engine speed
ranges from 13,000 to 13,800 r/min. Make sure the chain does not rotate when engine is idling. When
final adjustment is completed, the engine should idle, accelerate smoothly, and attain WOT per above
specifications.

NOTE : WOT and idle engine speed in field operation may vary from final adjustment specifications due
to changing ambient conditions and fuel. Engine speed variances should be within the safe ranges for
WOT and idle engine speed as listed in Section 1-2 Technical data, otherwise the carburetor should be
readjusted.
 CS-501SX, CS-501SXH
30 FUEL SYSTEM 501sx

4-7 Air shutter

When it is cold weather (outside air temperature

is 5 ºC/41ºF or lower) and acceleration is poor, re-
lease air shutter.
A 1. Air shutter is located in cylinder cover (A).

2. Picture shows normal position (sun mark) of air

shutter (B).

3. Reverse air shutter (B) to open position (snow-

man mark) to open air duct and introduce warm air
from cylinder side to carburetor side.

NOTE: In order to avoid carburetor vapor lock, re-

turn air shutter to normal position (sun mark) when
temperature is above freezing.
B
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 31
4-8 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 cleaner lid, air filter and cleaner case.

Disconnect fuel line from carburetor. Connect
Pressure tester 897803-30133 (A) to carburetor
fuel inlet.
A
2. Apply pressure approx. 98 kPa (1 kgf/cm2) (14
psi).

3. If pressure remains steady, follow step 4 and 5.

If pressure drops, proceed to step 6.

4. Pull starter grip. Pressure tester reading should

drop and remain above 49 kPa (0.5 kgf/cm2) (7
psi).

5. If reading does not drop, inspect inlet needle

valve for sticking or metering lever height is too
low.

6. If pressure drops at step 2, or if pressure drops

below standard figure at step 4, remove carburetor
from the unit, disconnecting pulse line, throttle rod
and choke knob.

7. Submerge carburetor in suitable clean solvent

to locate the leak by applying pressure approx. 98
kPa (1 kgf/cm2) (14 psi).

8. If air bubbles come out between pump cover

and carburetor body (B), inspect pump diaphragm,
C B pump gasket, and diaphragm seat of carburetor
body (Refer to “4-12 Inspecting diaphragm”).

9. If air bubbles come out from throttle bore (C),

inspect inlet valve, metering lever spring, and me-
tering lever height (Refer to “4-11 Inspecting inlet
needle valve”).
 CS-501SX, CS-501SXH
32 FUEL SYSTEM 501sx

4-9 Inspecting crankcase pulse passage

1. Drop a little oil in the end of pulse line (A) as

shown.

2. Remove spark plug and pull starter grip several

times. Oil should spit back from the hole.

3. If not, inspect whether pulse passage is clogged.

Repair or replace as required.

4-10 Inspecting metering lever height

A 1. Remove carburetor.
A
2. Remove four screws (A), metering diaphragm
B cover (B), metering diaphragm (C) and gasket (D).

F 3. Inspect metering lever (E) height by Metering

lever gauge 897563-19830 (F).
5
1 .3 Metering lever height: 1.65 mm (0.065 in) lower
than diaphragm seat (G).
0.4

1.65mm diaphragm seat (G)

1.5

G
1.6
5

4. If necessary, gently bend metering lever (E) up

or down to set metering lever to proper position.

NOTE: When metering lever is:

Too high → Fuel flooding occurs
Too low → Fuel starvation / overheating occurs
CS-501SX, CS-501SXH
501sx FUEL SYSTEM 33
4-11 Inspecting inlet needle valve
1. Remove metering lever (A) and pivot pin. Re-
move spring (B) and inlet needle valve (C).
A 2. Inspect inlet needle valve if worn or sticky. Clean
or replace as required.

NOTE: Causes of fuel flooding from carburetor to

cylinder are as 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

B clean solvent (do not use metal tools).

4. Reassemble inlet needle valve, spring, metering

lever and pivot pin.

C NOTE: Insure proper metering lever installation as

follows.

(1) Spring is seated in its hole at chamber floor.

(2) Spring is under dimple of metering lever.
(3) metering lever fork is holding inlet needle valve.

4-12 Inspecting diaphragm

1. Inspect metering diaphragm (A) for hardening,

B distortion, or pin hole. Replace as required.

2. Remove pump cover (B), pump diaphragm (C)

and pump gasket (D).
D
3. Inspect pump diaphragm (C) and replace if
C hardened or curled at valve tabs.

4. Inspect metering gasket (E) and pump gasket (D)

and replace if defective.

5. Inspect inlet screen (F) if blocked, remove and

F clean it, or replace.

6. Clean fuel passages in carburetor body with

compressed air.

NOTE: Before cleaning metering side with com-

pressed air, turn “H” needle clockwise until lightly
E seated and remove inlet needle valve. Otherwise,
main nozzle check valve and inlet needle valve
spring may be damaged by the compressed air.
A NOTE: When cleaning pump side with compressed
air, take care not to blow inlet screen (F) away.
 CS-501SX, CS-501SXH
34 FUEL SYSTEM 501sx

4-13 Replacing Welch plug

If engine does not run smoothly even after read-

justing carburetor and inspecting carburetor parts,
A inspect low speed ports on carburetor as follows:

1. Remove metering lever and related parts to pro-

B tect them from damage.

2. To remove Welch plug (A), punch the remover

tool (B) through Welch plug at low angle and pry it
out.

NOTE: Remover tool (B) and welch plug installer

(C) are included in Welch plug tool kit (Part num-
ber: 500-500).

3. Clean low speed ports with compressed air.

C
4. Place a new Welch plug over the opening and
gently tap it until flush using welch plug installer (C).

5. Install all removed parts to carburetor body.

CS-501SX, CS-501SXH
501sx FUEL SYSTEM 35
4-14 Installing carburetor

1. Connect fuel line (A) and pulse line (B) to carbu-

retor as shown.

2. Connect throttle rod (C) to carburetor.

B

3. Connect choke rod (D) with choke grommet (E)

to carburetor.

D
E

4. Secure carburetor (F) and carburetor elbow (G)

with bolts (H), washers (J) and bolts (K).

J
F

H
H

G
K
 CS-501SX, CS-501SXH
36 CLUTCH SYSTEM 501sx

5 CLUTCH SYSTEM

( A) Crankcase
(B) Collar
(C) Worm gear
(D) Clutch spring
(E) Clutch hub
(F) Clutch shoe
(G) Clutch assembly
(H) Needle bearing
(J) Clutch drum
(K) Sprocket
(L) Circular washer
(M) Nut

(G)
(E)

(M)

(C)

(A)
(B)

(F)
(L)

(K)
(E)
(D)

(H) (J)
CS-501SX, CS-501SXH
501sx CLUTCH SYSTEM 37
5-1 Inspecting clutch parts

1. Remove sprocket guard (A), cleaner lid (B) and

B
air filter.

NOTE: If starter assembly is installed, pull starter

rope out about 20 cm (8 in), and make a temporary
C knot (C) to prevent starter damage when installing
clutch assembly.

2. Disconnect spark plug cap and remove spark

plug.

A
3. Install clean rope (H) or piston stopper X644-
000020 in spark plug hole to stop crankshaft
H rotation.

4. Rotate clutch assembly clockwise by hand until

it cannot be rotated further.
F

5. Remove nut (D), circular washer (E) and sprock-

et (F).
D
6. Remove clutch drum (G) with needle bearing in-
side.
G
E

7. Loosen clutch assembly (Left-hand thread) ro-

tating clockwise with Clutch tool X640-000370 (J)
and remove it.

8. Remove collar and worm gear.

9. Inspect clutch shoes for wear and spring for

weakness or damage. Replace clutch parts as re-
quired.
J 10. Inspect clutch drum, sprocket, nut and circular
washer. Replace if deformed or worn out.

11. Inspect needle bearing, collar and worm gear

for damage, discoloration or deformation. Replace
as required.
 CS-501SX, CS-501SXH
38 CLUTCH SYSTEM 501sx

5-2 Replacing clutch parts

1. Install three clutch spring (A) to outside clutch

hub (B).
C
A
2. Set three clutch shoes (C) to each arms of
clutch hub (B) by flat head screwdriver.

3. Set inside clutch hub (D) to clutch assembly by

small flat head screwdriver.
B

5-3 Installing clutch assembly

1. Install collar (A) and worm gear (B) in the order

shown, making sure collar and worm gear are en-
gaging.
B C
2. Install clutch assembly (C; Left-hand thread) to
b crankshaft turning anticlockwise by hand until it
D 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”). While hold-
A ing starter grip, turn clutch assembly anticlockwise
until it cannot rotate further.
b
3. Tighten clutch assembly (C) with Clutch tool
X640-000370 (D).
CS-501SX, CS-501SXH
501sx CLUTCH SYSTEM 39
5-3 Installing clutch assembly (Continued)

4. Apply lithium-based grease to needle bearing (E).

Install clutch drum (F) and needle bearing (E) on
E crankshaft, placing the hands (b) of worm gear (B)
F f in cutouts (f) of clutch drum.

H 5. Install sprocket (G). Install circular washer (H),

facing flat side to sprocket (G).

6. Install nut (J).

7. Remove rope and reinstall all removed parts.

f G
J

flat side
H

J
 CS-501SX, CS-501SXH
40 CHAIN BRAKE SYSTEM 501sx

6 CHAIN BRAKE SYSTEM

( A ) Brake lever ( J ) Brake cover

( B ) Collar ( K ) Sprocket guard plate
( C ) Torsion spring ( L ) Sprocket guard plate
( D ) Brake seal plate ( M ) Chain tensioner
( E ) Brake band ( N ) Collar
( F ) Spring pin ( P ) Bevel gear
( G ) Coil spring ( R ) Sprocket guard
( H ) Brake connector ( S ) Crankcase

(M)
(L)
(K) (R)
(A)

(P)

(N)

(B)

(H)
(C)
(S)

(J)

(D)

(F) (G)
(E)

(S)
CS-501SX, CS-501SXH
501sx CHAIN BRAKE SYSTEM 41
6-1 Disassembling chain brake

WARNING DANGER
Wear eye protection and safety gloves when
disassembling or assembling chain brake to
protect eye and hand from injury.
A

1. Move brake lever (A) to chain brake engaging

B position.

2. Remove sprocket guard (B).

3. Remove screw (C) and two bolts (D) to remove

sprocket guard plate (E) and spike (F).

E F

4. Remove three bolts (G) and brake cover (H).

G 5. Inspect all the brake parts for damage. Replace
A
them as required.

H
6. Remove brake lever (Refer to “7-2 Inspecting
auto-oiler assembly and oil line”).

7. Inspect the brake lever for damage. Replace it

as required.
 CS-501SX, CS-501SXH
42 CHAIN BRAKE SYSTEM 501sx

6-2 Assembling brake parts

1. Install spring pin (B) through hole (a1) of brake

D C band (A). Hook end (a2) of brake band (A) through
c2
hole (c1) of brake connector (C). Tighten brake
E c1 band (A) and brake connector (C) with screw (D).
Slide in coil spring (E) to the end (c2) of brake con-
a2 nector (C).

a1

B A

C 2. Install brake band (A) and other parts (Refer to

c3 the above 1.) on crankcase (F) as shown. Make
sure the pin (B) in brake band (A) is engaging with
the groove (f1) of crankcase.
G 3. Install boss (G) through hole (c3) of brake con-
nector (C).

f1 F
B A

4. Set brake lever (H) with bolt (J).

H 5. Set the end of coil spring (E) on crankcase

J groove (f2) by pushing with flat head screwdriver
f2
as shown.
G
6. Tighten screw (K) and washer (L) in hole (f3) of
crankcase.
E
7. Set brake lever (H) with bolt (M) and coller (N)
on flywheel side.

f3 8. Apply molybdenum grease on entire compres-

sion spring and other friction parts.

9. Reinstall guide plate, brake cover and other

parts.
H

N
M

L K Flywheel side
CS-501SX, CS-501SXH
501sx SAW CHAIN LUBRICATION SYSTEM 43
7 SAW CHAIN LUBRICATION SYSTEM

( A ) Oil cap
( B ) O-ring (J)
( C ) Connector
( D ) Oil tank vent
( E ) Crankcase
( e ) Oil tank
(F)
( F ) Oil strainer
( G ) Oil line
( H ) Auto-oiler assembly
(e)
( J ) Oiler cover

(G)
(K)

(B)

(E)

(C)
(A) (B)
 CS-501SX, CS-501SXH
44 SAW CHAIN LUBRICATION SYSTEM 501sx

7-1 Inspecting oil cap and strainer

1. Remove oil cap.

2. Inspect oil cap for cracks and O-ring (A) for cuts
or damage. Replace worn or damaged parts as re-
quired.

3. Pull oil strainer (B) from oil tank using a wire

hook (C).
D

B
4. Remove oil strainer (B) from oil line (D) and
clean oil strainer in suitable solvent, or replace if
damaged.

B
CS-501SX, CS-501SXH
501sx SAW CHAIN LUBRICATION SYSTEM 45
7-2 Inspecting auto-oiler assembly and oil line

A 1. Remove three bolts (A) and brake cover (B).

2. Remove coil spring (C) using flat head screw-

driver (D).

E
C
3. Remove brake lever (E), coil spring (C), brake
band (F), oiler cover (G) and related parts.

D
F

4. Remove two bolts (H) and auto oiler assembly

(J).

5. Inspect auto-oiler assembly (J) for discoloration

J j2 or deformation. Inspect gear (j1) for wear, damage
and rotate smoothly. Inspect oil inlet (j2) and outlet
(j3) for clog. Replace as required.

j3
j1
 CS-501SX, CS-501SXH
46 SAW CHAIN LUBRICATION SYSTEM 501sx

7-3 Inspecting oil tank vent

NOTE: Oil tank vent prevents a vacuum from

A forming in oil tank when chain oil in the tank is con-
sumed.

1. Inspect oil tank vent (A) for clog or deformation.

Replace as requied.

2. Remove oil tank vent (A) using plyers (B).

3. Install oil tank vent (A) using suitable tool (C) as

A
shown.

C
CS-501SX, CS-501SXH
501sx ENGINE 47
8 ENGINE
( A ) Oil seal
( B ) Crankcase
( C) Ball bearing
( D) Crankshaft assembly
( E ) Washer
(Q)
( F ) Needle bearing
( G) Snap ring
( H) Piston pin
( J ) Piston
( K ) Piston ring
( L ) Cylinder
( M) Muffler
( N) Muffler gasket
(P) ( P ) Arrestor screen
( Q) Exhaust guide
( R) Intake bellows
( S ) Bellows holder
(R) ( T ) Intake insulator
(M)
(N)

(L)

(T)
(K) (S)

(G)
(J)

(H)
(G)

(F)

(E) (E)

(B)

(A)
(D)

(C)
(A)

(B)
 CS-501SX, CS-501SXH
48 ENGINE 501sx

8-1 Testing cylinder compression

NOTE: Test cylinder compression when engine is

cold.

1. Move ignition switch to STOP position. Then re-

A move 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.

3. If pressure is lower than approx. 75% of

standard compression pressure (Refer to “1-2
Technical data ”), inspect cylinder bore, piston, and
piston ring for wear or damage.

4. If pressure is more than approx. 125% of standard compression pressure, inspect cylinder combustion
chamber and exhaust port, piston crown, and muffler for carbon deposits.

NOTE: Compression pressure varies with volume of compression gauge tip occupying cylinder combus-
tion chamber. If gauge tip volume is considerably different from spark plug volume, it is recommended to
measure and note compression pressure of brand-new engines as standard pressure in advance.

8-2 Cleaning cooling air passages

1. Remove cleaner lid, air filter and cylinder cover.

Remove starter assembly (Refer to “2-1 Disassem-
bling starter assembly”).

WARNING DANGER
Always wear eye protection when using
compressed air for cleaning. Otherwise,
eye damage can occur from flying particles.
A
2. Inspect cylinder cooling fins (A) for blockage
with dirt and/or saw dust. Clean them with wooden
or plastic stick or compressed air as required.

3. Install all removed parts.

CS-501SX, CS-501SXH
501sx ENGINE 49
8-3 Inspecting muffler and exhaust port

1. Remove cleaner lid, air filter and cylinder cover.

2. Remove muffler with muffler gasket.

3. Inspect cylinder exhaust port and clean the port

using wooden or plastic stick 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 or cylin-
der.

NOTE: Replace muffler gasket with new one when

removing muffler.

4. Remove exhaust guides (A) and spark arrestor

screen (B) from muffler.

5. Remove carbon deposits from spark arrestor

A
screen and exhaust guides. If screen has heavy
deposits, replace with new one.

6. Reinstall spark arrestor screen and exhaust

guides to muffler.

7. Reinstall muffler with new muffler gasket.

NOTE: Before reinstalling muffler, apply 2-stroke

oil on muffler gasket surface and temporarily paste
C muffler gasket (C) on cylinder as shown, in order
to avoid damage to muffler gasket from wall (D) of
crankcase.
D
NOTE: New bolts for bolt hole (E) and (F) are pre-
coated with sealant on the thread. If the sealant
is peeled off, apply thread locking sealant (Loctite
#242, ThreeBond #1324 or equivalent).
E F
 CS-501SX, CS-501SXH
50 ENGINE 501sx

8-4 Testing crankcase and cylinder seal

1. Remove cleaner lid, air filter and cylinder cover.

A 2. Disconnect fuel line, pulse line and choke rod
B from carburetor, and remove carburetor from the
unit.

3. To seal intake port, install Pressure rubber plug

897826-16131 (A) between intake insulator and
carburetor, using carburetor screws (C). Install
Pressure plate 897827-16131 (B) between carbu-
retor and screw heads as spacer. Tighten screws
(C).
C

D 4. Loosen 4 muffler bolts. To seal exhaust port,

insert pressure rubber plug 91041 (D) between cyl-
inder exhaust port and muffler gasket (E), until the
rubber plug covers exhaust port.

E D 5. Tighten upper 2 bolts of muffler.

6. Remove decompressor (F) and install plug

101115-37531 (G) and O-ring 900720-00009 (H)
as shown.
F

7. Connect pressure / vacuum tester 91149 (J) to

pulse line using provided pipe joint (K).

8. Apply pressure approx. 50 kPa (0.5 bar) (7.1

psi) by the tester (J).

9. If the pressure drops, leakage may occur.

10. Leakage may occur from crankcase seam,

G cylinder base, oil seal and spark plug. Use soapy
H
water to locate leakage.

11. Apply negative pressure approx. 30 kPa (0.3

J bar) (4.3 psi) by the tester (J).

12. If the pressure decreases, leakage may occur

from oil seal. Inspect oil seal for damage or wear.

13. Remove pressure / vacuum tester (J), pipe

K
joint (K) from pulse pipe. Remove pressure rubber
plugs (A) (D) and pressure plate (B) from intake
bellows and exhaust port. Remove plug (G) and O-
ring (H) and install decompressor (F).
CS-501SX, CS-501SXH
501sx ENGINE 51
8-5 Inspecting cylinder

1. Remove carburetor from the unit (Refer to “4-5-1

A
Replacing fuel line”).

2. Remove muffler with muffler gasket (Refer to “8-3

Inspecting muffler and exhaust port”).

3. Remove 4 bolts from cylinder base through

holes (A).

4. Inspect cylinder combustion chamber and clean

with a plastic or wooden scraper if carbon is found.

NOTE: Do not use metal tools, or damage to cylin-

der wall may result.
B
5. Inspect cylinder wall and replace with new one
if plating is worn, peeled away, scored or exposing
cylinder base metal.

6. Install intake bellows (B) to cylinder.

B 7. Install bellows holder (C) on intake bellows (B).

8. Install intake insulator (D) on intake bellows (B).

B
9. Install collar (E) in intake bellows (B).
E

10. Install cylinder in crankcase (F).

F
 CS-501SX, CS-501SXH
52 ENGINE 501sx

8-6 Inspecting piston and piston ring

1. Inspect piston ring and replace it if broken or

A
scored, or if it exceeds service limits (Refer to “1-
5”).

2. Inspect piston crown. Clean with fine sand pa-

per, oil stone, or soft cleaning brush (A) if carbon is
found.

3. Inspect top land, ring groove and skirt. Clean

them with soft cleaning brush (A) if carbon is
found.

NOTE: Do not use square end of broken piston

ring when cleaning piston ring groove, otherwise
piston ring groove might be damaged.

4. Remove snap ring (B) from both sides of piston

D
pin, using small flat head screwdriver (C).

NOTE: Piston holder 897719-02830 (D) is recom-

mended.

5. Push piston pin out from piston.

NOTE: If piston pin is tight, use Piston pin tool

F 897702-30131 (E) with adapter (F) stamped “11”
E on an end.

6. Inspect needle bearing and washers, and re-

place if wear or discoloration is noted.
CS-501SX, CS-501SXH
501sx ENGINE 53
8-7 Replacing oil seal
1. Pry oil seal from crankcase.

NOTE: Be careful not to damage crankshaft and

oil seal housing.

NOTE: Before removing flywheel side oil seal, re-

move woodruff key.

A 2. Remove oil seal (A) using flat head screwdriver.

3. Apply lithium based grease, ECHO XTended

Protection Lubricant or Red Armor Lubricant on in-
ner rubber lips of new oil seal.
C

4. Lubricate circumferences of new oil seal with

A high melting point grease.

5. Push in new oil seal (A) until flush with crank-

case surface (B) using Oil seal tool X646-000360
B (C).

8-8 Disassembling crankcase

A 1. Referring to “11-1 Disassembly chart”, remove

necessary parts for crankcase disassembly.

2. Remove 5 bolts (A) from crankcase.

3. Install long 3 bolts (B) (length: approx. 80 mm)

B on one side of crankcase halves (in the picture, fly-
wheel side is shown).

4. Tighten bolts (B) to pull crankcase halves apart.

5. Crankshaft remains on the other side of crank-

case halves, and can be removed by the same
procedure with long 3 bolts (B).

6. Clean and inspect crankshaft and crankcase for

damage and discoloration.
 CS-501SX, CS-501SXH
54 ENGINE 501sx

8-9 Replacing ball bearing and oil seal

1. After disassembling crankshaft, check ball bear-

ing for smooth rotation. If rough, replace it (them)
with new one.

NOTE: At the same time, replace oil seal with new

one.
B
A
D
2. Remove ball bearing from crankcase half using
bearing tool 897701-14732 as follows.

3. Set shaft (A) through oil seal (B) and ball

bearing (C), with boss (D) as shown.
Crankcase C
4. Tighten shaft (A) with wrench to remove ball
bearing (C) and Oil seal (B).

5. Coat bearing housing in crankcase with a lithium

based grease.
G
6. Set ball bearing with shaft (A), adapter (G) (inner
dia. 15 mm, outer dia. 40 mm) and boss (D).
A NOTE: Set adapter (G) mating full flat side (g) to
ball bearing.

7. Tighten shaft (A) with wrench to press ball bear-

ing into the crankcase half until flush.
D
8. Check that bearing rotates smoothly.

D
G

A
Crankcase
C
CS-501SX, CS-501SXH
501sx ENGINE 55
8-9 Replacing ball bearing and oil seal (continued)

9. Apply lithium based grease, ECHO XTended

C Protection Lubricant or Red Armor Lubricant on in-
ner rubber lips of new oil seal.
A 10. Lubricate circumferences of new oil seal with
high melting point grease.
B
11. Push in new oil seal (A) until flush with crank-
case surface (B) using Oil seal tool X646-000360
(C).

8-10 Assembling crankshaft and crankcase

1. Clean mating surface of each crankcase half.

B 2. Insert crankshaft clutch end (A) into clutch side
b crankcase half (B) until properly seated.

NOTE: If it is hard to insert crankshaft to crank-

C case, preheat ball bearing for easier installation.

3. Put new crankcase gasket (C) on clutch side

crankcase half (B).

4. Reassemble both crankcase halves together en-

b suring that dowel pins (b) on clutch side crankcase
half (B) are properly seated in holes on the other
half.

A 5. Tighten 3 bolts (D) diagonally to secure crank-

case halves together, and check crankshaft for
D smooth rotation.

6. Tighten other 2 bolts.

NOTE: Tighten bolts referring to “1-3 Torque lim-

its”.
 CS-501SX, CS-501SXH
56 ENGINE 501sx

8-11 Installing piston

1. Place piston over the small end of connecting

A rod, so that the arrow mark (A) on piston points
front as shown.

2. Insert piston pin guide (B) stamped “11”, through

piston, washers (C) and needle bearing (D) in con-
necting rod as shown.

NOTE: Piston pin guide (B) is included in piston

pin tool 897702-30131.

3. Insert piston pin (E) in piston pushing out piston

pin guide (B) using piston pin tool 897702-30131
B (G) and Piston holder 897719-02830 (F).

4. Install new snap rings to piston using small flat

C D C head screwdriver and be sure that they are cor-
rectly seated in the grooves.

NOTE: If it is hard to install snap rings, modify flat

head screwdriver end as shown to hook snap ring.

F E
G

B
CS-501SX, CS-501SXH
501sx ENGINE 57
8-12 Installing piston ring and cylinder

1. Install piston ring on piston, ensuring the end

A gaps of piston ring are properly positioned around
locating pin (A) as shown.

2. Temporarily paste new cylinder gasket (B) on

cylinder base with a little glue for easier installation
of cylinder.
b
C NOTE: Projection (b) of cylinder gasket (B) is to-
wards brake lever side.

E 3. Apply oil to piston ring and internal wall of cylin-

der.

4. Install cylinder (C) with intake bellows, bellows

holder and intake insulator with over piston, ensur-
B ing that the exhaust side of cylinder should face
front as shown.

NOTE: When installing cylinder, it is convenient to

use Piston holder 897719-02830 (E) to stabilize
piston.

NOTE: When installing piston in cylinder, do not

twist cylinder to avoid breakage of piston ring and
scoring cylinder bore.

5. Reinstall all removed parts in place.

 CS-501SX, CS-501SXH
58 REAR HANDLE AND CONTROL SYSTEM 501sx

9 REAR HANDLE AND CONTROL SYSTEM

( A) Rear handle
(B) Spring pin
(C) Torsion spring
(D) Throttle trigger
(E) Throttle lockout
(F) Rear handle cover
(G) Grip
(H) Cushions
(J) (J) Cushion caps

(H)

(F)

(E)

(B)
(H)

(D)

(C)

(J)

(G)

(A)
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 59
9-1 Replacing cushions

1. Remove four cushion caps (A) (Refer to cushion

caps (J) of “9 REAR HANDLE AND CONTROL
A
SYSTEM”on previous page).

2. Remove a bolt (B), four cushion caps (A), four

bolts (C) under cushion caps (A) and rear handle
from unit.

B
A

A
C under cushion cap

3. Inspect cushions (D) for cracking and wear. If

damaged replace with new cushions as follows.

4. To remove cushions (D), push by hand in direc-

tion of arrows.

5. Install new cushions by pushing in direction of

arrows.
 CS-501SX, CS-501SXH
60 REAR HANDLE AND CONTROL SYSTEM 501sx

9-1 Replacing cushions (continued)

6. Inspect cushions (E) for cracking or wear. If

damaged, replace with new cushions as follows.

7. To remove cushions (E), pull by hand in direc-

E tion of arrows.

8. Clean the surrounding of cushion boss (F) if ad-

hesive is struck.

f F
E
9. Install new cushion (E) mating groove (e) to pro-
jection (f) of the boss (F).

10. Apply adhesive Loctite 422 or equivalent to the

base of cushion (E).

e
11. Inspect cushions (G) for cracking or wear. If
damaged, replace with new cushions as follows.

12. To remove cushions (G), pull by hand in direc-

tion of arrows.

13. Clean the surrounding of cushion hole (H) if

adhesive is struck.

14. Install new cushion (G) by pushing in direction

of arrows.

15. Apply adhesive Loctite 422 or equivalent to the

base of cushion (G).

16. Reassemble rear handle to the unit. Reassem-

ble all related parts.

H
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 61
9-2 Replacing throttle trigger

1. Loosen screw (A) and remove grip (B), rear

handle cover (C) and throttle lockout (D).
D

2. Inspect grip (B), rear handle cover (C) and throt-

D tle lockout (D) for cracking or wear. If damaged,
replace it as required.

H 3. Push out spring pin (E) from rear handle using

Spring pin tool 897724-01361 (F).

4. Remove throttle trigger (G) together with torsion

spring (H).
F

G
 CS-501SX, CS-501SXH
62 REAR HANDLE AND CONTROL SYSTEM 501sx

9-2 Replacing throttle trigger (continued)

5. Set torsion spring (H) on throttle trigger (G) as

G shown.

H
6. Install throttle trigger (G) with torsion spring (H)
and insert spring pin (E) as follows.

1) Insert spring pin (E) in the hole of rear handle

so the tip of spring pin does not protrude inside
G handle.
H 2) Align spring pin (E) and the hole of throttle
trigger (G) with torsion spring (H), and insert
spring pin (E) in the hole of throttle trigger (G).

3) Lightly tap in spring pin (E), using spring pin

E
tool 897724-01361 (F).
F

7. Install throttle lockout (D) with spring pin (E) as

D
shown.

8. Install rear handle cover (C) on rear handle (J),

D setting torsion spring (H) with throttle lockout (D)
as shown (Refer to “9-3-3 Replacing rear handle
heater”).
C

9. Tighten screw (A) to secure rear handle cover

(C). Check throttle trigger (G) and throttle lockout
(D) for correct movement.
A

J
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 63
9-3 Service hint for heated handle (CS-501SXH only)

(A)
(C)

(D)

(F)

(B)

(E)

(L)
(G)

(A) Front handle assembly (with heater) (H)

(B) Band
(C) Handle cover
(D) Heater switch
(E) Nut
(F) Rear handle cover
(G) Rear handle
(H) Cushion
(J) Rear handle heater
(K) Handle grip
(L) Stator assembly

(J)
(K)
 CS-501SX, CS-501SXH
64 REAR HANDLE AND CONTROL SYSTEM 501sx

9-3-1 Inspecting heated handle

Inspecting stator assembly

A 1. Remove air cleaner cover (A), air filter and han-
dle cover (B).

2. Disconnect stator lead coupler (C).

NOTE: If it is not clear which is stator lead coupler

B (C), remove carburetor and carburetor elbow, and
check where the lead is connected to.

3. Connect one probe of ohm-meter or multi-meter

to stator lead (D) as shown.

4. Connect the other probe to heater switch lever (E)

or a clean ground as shown.

E C

5. Tester should show that the circuit is in conduct-

ing state.

6. If stator assembly is defective, replace with a

new one (Refer to 9-3-2 “Replacing stator assem-
bly”).
B

Inspecting front handle heater

1. Disconnect stator lead coupler (A) and rear han-

dle heater coupler (B).
A 2. Connect one probe of ohm-meter or multi-meter
to one lead of front handle heater (C) as shown.

3. Connect the other probe to other lead of front

handle heater (D) as shown.

C D 4. Tester should show that the circuit is in conduct-

ing state.

5. If front handle heater is defective, replace with a

new one.
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 65
9-3-1 Inspecting heated handle (continued)

Inspecting rear handle heater

1. Disconnect rear handle heater lead coupler (A).

NOTE: If it is not clear which is rear handle heater

lead coupler (A), remove carburetor and carburetor
elbow, and check where the lead is connected to.

2. Connect one probe of ohm-meter or multi-meter

to rear handle heater lead (B) as shown.

3. Connect the other probe to heater switch termi-

nal (C) as shown.

4. Tester should show that the circuit is in conduct-

ing state.

5. If rear handle heater is defective, replace with

a new one (Refer to 9-3-3 “Replacing rear handle
heater”).
A

Inspecting heater switch

1. Connect one probe of ohm-meter or multi-meter

to heater switch terminal (A) as shown.

2. Connect the other probe to heater switch lever (B)

as shown.

3. When heater switch is in “RUN” position, tester

should show that the circuit is in conducting state.

4. When heater switch is in “STOP” position, tester

should indicate infinite resistance.

5. If heater switch is defective, replace with a new

one (Refer to 9-3-4 “Replacing heater switch”).

B
 CS-501SX, CS-501SXH
66 REAR HANDLE AND CONTROL SYSTEM 501sx

9-3-2 Replacing stator assembly

1. Remove air cleaner cover and handle cover.

2. Remove four bolts and remove starter assembly

(A) from unit.

3. Disconnect stator lead coupler (B).

NOTE: If it is not clear which is stator lead coupler

(B), remove carburetor and carburetor elbow, and
check where the lead is connected to.

4. Install piston stopper X644-000020 (C) into

spark plug hole by hand to stop crankshaft rota-
tion.
C
5. Remove fan cover (D).

6. Remove nut (E) by rotating counterclockwise.

D NOTE: Do not use power tool to remove nut (E).
E Otherwise, piston damage may occur.

7. Set puller Y089-000111 (F) on flywheel as

shown.

8. Tighten two nuts (G) on the puller alternately to

F remove flywheel.

G
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 67
9-3-2 Replacing stator assembly (continued)

9. Remove two bolts (H) and remove stator as-

sembly (J).

J 10. Install new stator assembly, and connect stator

lead coupler (B).

11. Reinstall disassembled parts.

9-3-3 Replacing rear handle heater

1. Remove air cleaner cover, air filter and handle

cover.

2. Remove screw (A). Remove handle grip (B) and

rear handle cover (C).

3. Remove two bolts (D) and remove carburetor (E)

and carburetor elbow (F).
D E

4. Disconnect heater switch coupler (G) and rear

G handle heater coupler (H).

H
 CS-501SX, CS-501SXH
68 REAR HANDLE AND CONTROL SYSTEM 501sx

9-3-3 Replacing rear handle heater (continued)

4. Remove boots (J) and + rear handle heater.

J

J 5. Install new rear handle heater.

6. Pass the rear handle heater lead (K) as shown.

7. Pass the rear handle heater lead (L) as shown.

8. Reinstall boots (J) to each lead terminal as

shown.

L
9. Connect rear handle heater lead (K) to heater
switch lead (M) and rear handle heater lead (N) to
coupler (H).

NOTE: Check if heater switch lead (M) is mounted

K without contacting with the side (P).

M
P
CS-501SX, CS-501SXH
501sx REAR HANDLE AND CONTROL SYSTEM 69
9-3-3 Replacing rear handle heater (continued)

10. Insert the tab (e) of rear handle cover (E) into
rear handle, and install rear handle cover (E) on
E rear handle, while pushing the rear handle cover (E)
as shown.

e
E

11. Insert the tab (d) of handle grip (D) into rear
handle, and install handle grip (D) as shown.
D d

12. Reinstall disassembled parts.

9-3-4 Replacing heater switch

1. Remove air cleaner cover and air filter.

2. Remove carburetor and carburetor elbow.

A 3. Disconnect heater switch coupler (A) and re-
move heater switch.

4. Install new heater switch (B) as shown.

5. Connect heater switch coupler (A).

B
6. Reinstall disassembled parts.
 CS-501SX, CS-501SXH
70 GUIDE BAR MOUNTING SYSTEM 501sx

10 GUIDE BAR MOUNTING SYSTEM

(A) Sprocket guard

(B) Inner sprocket guide plate (D)
(C) Outer sprocket guide plate
(A)
(D) Tensioner screw
(E)
(E) Chain tensioner (C)
(F) Collar
(B)
(G) Bevel gear
(H) Bevel gear
(J) Protector

(G)
(H)
(F)

(J)
CS-501SX, CS-501SXH
501sx GUIDE BAR MOUNTING SYSTEM 71
10-1 Replacing chain tensioner

B A 1. Remove sprocket guard (A) from the unit.

2. Remove outer guide plate (B) and collar (C)

from sprocket guard. Remove tensioner screw (D),
chain tensioner (E) and bevel gears (F) (G).

3. Inspect them for damage or wear. Replace as

H
required.

4. Install bevel gear (G) into sprocket guard.

5. Screw chain tensioner (E) on tensioner screw

(D).
D 6. Insert bevel gear (F) in tensioner screw (D) with
G
chain tensioner (E).
F
E
C

7. Install sub-assembled tensioner screw in slot (H)

of sprocket guard, confirming engagement of bevel
gear (F) and (G).

H
D 8. Reassemble outer guide plate (B) and collar (C).

G
F

10-2 Replacing guide bar stud

1. Remove oil cap and empty oil from tank.

2. Tap guide bar stud lightly with copper hammer,

and push into oil tank. Remove stud from oil tank.
 CS-501SX, CS-501SXH
72 GUIDE BAR MOUNTING SYSTEM 501sx

10-3 Installing guide bar stud

1. Apply adhesive (Loctite #609, ThreeBond 1373

or equivalent) to un-threaded part (a) of new guide
B bar stud (A).

a 2. Install new stud (A) to the stud-hole of oil tank

using a pair of tweezers (B).

3. Lightly tap square head of stud with long bar tool

(C) and hammer.

4. Install spacer [Bore: 8 to 10 mm (0.32 to 0.39

in), Height: 10 to 12 mm (0.39 to 0.47 in)] (D).
D
Thread M8 nut (E) clockwise onto stud. Turn nut
clockwise to pull stud through oil tank mounting
D
E hole. The square head of the stud should seat
against the oil tank wall parallel with inner ribs.

E
5. Look into oil tank and check if square head (F)
of the stud is properly seated inside crankcase. If
not, install two nuts to the stud and secure them
F against each other.

6. Turn nut (G) clockwise or nut (H) counterclock-

wise to correct the position of the square head.
G H 7. Repeat step 4 to seat the stud correctly in
square hollow inside oil tank.

8. Install all removed parts.

CS-501SX, CS-501SXH
501sx MAINTENANCE GUIDE 73
11 MAINTENANCE GUIDE
11-1 Disassembly chart

Cleaner
Sprocket lid Starter
guard assembly
Cylinder
(2-1,5-1,6-1) (2-1)
cover

Clutch Muffler
Brake cover Spark plug Air filter
drum (8-3)
(6-1,7-2) (3-3) (4-1)
(5-1,5-3)

Brake lever Clutch assembly,

(6-1,7-2) Worm gear Carburetor
(5-1,5-3) (4-8,4-10 to14)
Rear
handle
(9-2)
Brake band Auto-oiler
(6-2) (7-2)
Ignition
Cushions coil
(9-2) (3-8)

Flywheel
(3-10)

Crankcase,
Cylinder, Piston ring
(8-5, 8-6, 8-8)

Clutch side Clutch side Starter side

Starter side
Piston ball bearing
oil seal ball bearing oil seal
(8-6) (8-9)
(8-7) (8-9) (8-7)

Crankshaft
assembly
(8-8,8-10)
 CS-501SX, CS-501SXH
74 MAINTENANCE GUIDE 501sx

11-2 Troubleshooting guide

TROUBLE
Engine does not crank. 01
Engine does not start. 02
Fuel leaks. 03
Idling is not stable. 04
Acceleration is poor. 05
Engine stalls at high speed. 06
Engine lacks power. 07
Engine seizure / overheat 08
Engine misfires. 09
Engine / others are extremely noisy. 10
Fuel consumption is excessive. 11
Vibration is excessive. 12
Engine does not stop. 13
Oiler does not function. 14
Saw chain does not cut well. 15

INSPECTING REFERENCES Inspecting first.

Starter system 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Starter pawl / spring 2-4
Starter drum / rope 2-2
Rewind spring 2-3
Ignition system 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Sparks 3-2
Spark plug 3-3
Spark plug cap / coil 3-7
Ignition switch 3-4
Ignition coil 3-6, 3-8
Pole shoe air gaps 3-9
Flywheel 3-10
Flywheel key 3-10
Clutch system 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Clutch shoes / spring / bearing 5-1 to 5-3
Clutch drum 5-1, 5-3
Sprocket 1-5, 5-1
(Continued)
CS-501SX, CS-501SXH
501sx MAINTENANCE GUIDE 75
11-2 Troubleshooting guide (continued)

INSPECTING REFERENCES Inspecting first.

Fuel system / Carburetor 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Air filter 4-1
Fuel cap / strainer 4-2
Carburetor adjustment 4-6
Fuel tank / line / vent 4-3 to 4-5
Carburetor leakage 4-8
Carburetor metering lever height 4-10
Carburetor diaphragms 4-12
Carburetor inlet needle valve 4-11
Welch plug 4-13
Crankcase pulse passage 4-9
Throttle trigger 9-2
Fuel (octane / freshness / purity) 4-6-1
2-stroke oil (grade / mix ratio) 4-6-1
Saw chain lubrication system 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Oil cap 7-1
Oil tank / line / strainer 7-1, 7-2
Oil tank vent 7-3
Auto-oiler 7-2
Guide bar / Oil holes Clean
Engine 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Cooling air passage 8-2
Muffler / Exhaust port 8-3
Cylinder compression 1-2, 8-1
Crankcase / cylinder seal 8-4
Crankcase / Cylinder 8-4, 8-8
Piston / Piston ring 8-6
Crankshaft / Ball bearings 8-8, 8-9
Others 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01
Chain brake 6-1, 6-2
Cushions 9-1
Chain tensioner 10-1
Saw chain Replace / Sharpen
 CS-501SX, CS-501SXH
76 MAINTENANCE GUIDE 501sx

11-3 Service Intervals

Intervals
Inspecting point Service Reference 3 months
Before use or
100 hour
Screws and bolts * Retighten / Replace
Air filter Inspect / Replace / Clean 4-1
Choke system Inspect / Replace
Carburetor Inspect / Repair 4-8 to 4-14
Fuel leaks Inspect / Repair 4-2, 4-3 **
Fuel line Inspect / Repair 4-3, 4-5-1
Cooling system Inspect / Clean 8-2
Spark plug Inspect / Replace 3-3
Fuel strainer Clean / Replace 4-2
Leads and connections Inspect / Repair 3-5
Fuel tank Clean inside. 4-3
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
Guide bar Inspect / Clean
Chain brake Inspect / Repair 6-1, 6-2

IMPORTANT: Service intervals shown above are maximum. Actual use and your experience will determine
the frequency of required maintenance.
* Retighten the following screws and bolts after first 1 week use, and every 3 months.
Cylinder cover screws (3 pcs.)
Starter assembly screws (4 pcs.)
Cushion bolts (4 pcs.)
Front handle screws (5 pcs.)
Muffler bolts (4 pcs.)
** Inspect after every refuel.
CS-501SX, CS-501SXH
501sx MEMORANDUM 77
 Published by
YAMABIKO Corp.
Tokyo Japan
1902