TABLE OF CONTENTS
CS-501SX, CS-501SXH
501sx
1
Page Page
1 SERVICE INFORMATION ..................................... 2
1-1 Specifi cations ...................................................2
1-2 Technical data ..................................................3
1-3 Torque limits .....................................................4
1-4 Special repairing materials ...............................4
1-5 Service Limits ...................................................5
1-6 Special tools .....................................................6
2 STARTER SYSTEM ..............................................7
2-1 Disassembling starter assembly .......................8
2-2 Replacing starter rope ......................................9
2-3 Assembling starter ..........................................10
2-4 Replacing starter pawl ....................................12
3 IGNITION SYSTEM ............................................. 13
3-1 Troubleshooting guide ....................................14
3-2 Testing spark ..................................................15
3-3 Inspecting spark plug .....................................15
3-4 Inspecting ignition switch ................................16
3-5 Replacing ignition switch ................................16
3-6 Inspecting ignition coil resistance ...................17
3-7 Replacing spark plug cap and coil..................18
3-8 Replacing ignition coil .....................................18
3-9 Setting pole shoe air gaps ..............................19
3-10 Inspecting fl ywheel and key ...........................19
4 FUEL SYSTEM ...................................................21
4-1 Inspecting air fi lter ..........................................22
4-2 Inspecting fuel cap and fuel strainer...............22
4-3 Inspecting fuel tank and line ...........................23
4-4 Inspecting and replacing tank vent .................24
4-5-1 Replacing fuel line ..........................................26
4-5-2 Replacing fuel vent pipe .................................27
4-6 Adjusting carburetor .......................................28
4-6-1 General adjustment rules ...............................28
4-6-2 Initial setting Throttle adjust screw, L mixture
needle and H mixture needle .........................28
4-6-3 Adjusting carburetor .......................................29
4-7 Air shutter .......................................................30
4-8 Testing carburetor ...........................................31
4-9 Inspecting crankcase pulse passage .............32
4-10 Inspecting metering lever height ....................32
4-11 Inspecting inlet needle valve ..........................33
4-12 Inspecting diaphragm .....................................33
4-13 Replacing Welch plug .....................................34
4-14 Installing carburetor ........................................35
5 CLUTCH SYSTEM ..............................................36
5-1 Inspectng clutch parts ....................................37
5-2 Replacing clutch parts ....................................38
5-3 Installing clutch assembly ...............................38
6 CHAIN BRAKE SYSTEM ....................................40
6-1 Disassembling chain brake ............................41
6-2 Assembling brake parts ..................................42
7 SAW CHAIN LUBRICATION SYSTEM ...............43
7-1 Inspecting oil cap and strainer ........................44
7-2 Inspecting auto-oiler assembly and oil line.....45
7-3 Inspecting oil tank vent ...................................46
8 ENGINE ............................................................... 47
8-1 Testing cylinder compression .........................48
8-2 Cleaning cooling air passages .......................48
8-3 Inspecting muffl er and exhaust port ...............49
8-4 Testing crankcase and cylinder seal ...............50
8-5 Inspecting cylinder ..........................................51
8-6 Inspecting piston and piston ring ....................52
8-7 Replacing oil seal ...........................................53
8-8 Disassembling crankcase ...............................54
8-9 Replacing ball bearing and oil seal.................54
8-10 Assembling crankshaft and crankcase ...........55
8-11 Installing piston ...............................................56
8-12 Installing piston ring and cylinder ...................57
9 REAR HANDLE AND CONTROL SYSTEM .......58
9-1 Replacing cushions ........................................59
9-2 Replacing throttle trigger ................................61
9-3
Service hint for heated handle
(CS-501SXH only)
...63
9-3-1 Inspecting heated handle ...............................64
9-3-2 Replacing stator assembly .............................66
9-3-3 Replacing rear handle heater .........................67
9-3-4 Replacing heater switch .................................69
10 GUIDE BAR MOUNTING SYSTEM ..................70
10-1 Replacing chain tensioner ..............................71
10-2 Replacing guide bar stud ................................71
10-3 Installing guide bar stud .................................72
11 MAINTENANCE GUIDE .................................... 73
11-1 Disassembly Chart .........................................73
11-2 Troubleshooting guide ....................................74
11-3 Service Intervals .............................................76
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