Author Topic: ECHO CS-440EVL: OOPS installing new intake adapter  (Read 1923 times)

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Offline North West Farmer

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ECHO CS-440EVL: OOPS installing new intake adapter
« on: November 19, 2011, 05:53:27 am »
This is my first post attempt on Chainsaw Repair so will give it a shot.

I have an ECHO CS-440EVL, very low hours, historically has started and run like a new chainsaw.  On recent use it began to behave as though is was leaning out.  Carb. adjustment attempts had little affect.

Checked the normal items, fuel filter-not too good, fuel intake hose-spongy and fragile in area below normal fuel level,  carb-not much use, but saw is several years old, both diaphragms stiff, fuel inlet screen-covered with loose, but considerable Debris, intake adapter-found with quarter inch slit in adapter neck.  As indicated, found potential issues so decided to replace fuel filter, lines, rebuild carb, cleaning thoroughly, replaced diaphragms gaskets and inlet screen, replace intake adapter.

All work went very well, everything hospital clean.  Tore down saw to the point needed to replace the items mentioned above.  Following reassembly, fueled unit and added chain oil.  Everything had gone so nicely, expectation was for good start and after carb adjustment I was looking forward to a like new chainsaw.

Upon start attempt, it popped after the first pull. There was no second pull, piston was locked in position.  Did a little careful testing and nothing was moving.  Removed carb., and in that process I noticed that a small lock washer and a small standard washer were missing off of one stud that connects the carb. body to the adapter plate.  At that point I experienced an unspeakable sinking feeling and upon further examination down the intake I could see a small dent on the piston skirt and a shallow scrape on the side of the piston.

These observations meant I needed to tear the saw down to a point at which I could determine the extent of the damage.  That is the reason for my post.  I have not torn a saw down beyond the point of changing a piston and cylinder head.  This involves removing the crank, splitting the crank case and advice in those areas would be appreciated.  I have searched the threads and was unable to locate one describing the processes mentioned above.

Presently, the saw is disassembled to the point of removing the cylinder head, the piston, the clutch assembly from the crank shaft and of course all miscellaneous items required to gain access to these last items mentioned.  Amazingly, the only thing that is definitely toast is the piston, having multiple small chunks broken off and the rings are in several peaces.  Multiple small portions of piston and ring material have been found and removed.  Nothing else appears to be damaged, but the crank is still in the crank case so problems with the bearings or in the bottom of the crank case are possible.

Now, questions and/or recommendations:
     1.  Remove the flywheel via supporting the flywheel and with brass
      hammer, tap the flywheel end of the crank to release flywheel or
      use standard two armed puller and remove the flywheel?

     2.   Procedure to separate the case.  Remove bolts, and carefully 
      bump the case with a rubber hammer to separate halves?

     3.   When reassembling the crank case using a gasket, should
     some type of gasket compound be applied to the gasket to assist
     in the assembly process and improve the final seal quality?

That is my present situation and those are the primary concerns that come to mind at this point in time. If you have any suggestions or concerns I would definitely appreciate your input.

I have been told this is the forum most likely to provide high quality information and guidance in dealing with chainsaw problems. thus my arrival on this forum and on this thread, hopefully, I have selected the appropriate thread.

Your assistance in helping me attempt to bring this very good ECHO chainsaw back to life would be sincerely appreciated.  If needed, I will attempt to provide pictures, depending upon my ability to figure out how to upload pictures to the site.

Nick, North West Farmer

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Offline man of stihl

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #1 on: November 19, 2011, 07:53:25 am »
It doesn't look like you will have to seperate the crankcase or pull the flywheel to get at the piston. It is a clamshell design but the cylinder comes off by itself also. http://www.ereplacementparts.com/echo-cs440-c09112001001-c09112999999-chainsaw-parts-c-35043_35970_36771.html Go to page F.
Ron

Offline brokenbudget

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #2 on: November 19, 2011, 09:42:38 am »
if the cylinder is beyond repair, you'll need to order the whole shortblock. they don't sell the cylinder separately. only the piston.
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Offline North West Farmer

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #3 on: November 19, 2011, 10:40:02 am »
man of stihl,

I have removed the top end and the piston.  The piston is toast and the cylinder walls look and feel good.  I hope to get some pictures off shortly so you can have an up close view of the top end interior.

The case needs to be split in order to evaluate any possible damage to the bottom end, in particular to determine if any debris may have gotten into the open side of the bearings.  There seems to be quite a bit of very small material in the bottom of the crank case, which might involve the bearings.

The parts I know I need and some I expect to need have been ordered from the site you recommended.

Still would like some recommendation(s) on the best procedure for splitting the case.

Thanks much for your rapid reply.

Nick, North West farmer

Offline Cut4fun .

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #4 on: November 19, 2011, 10:58:32 am »
I'm confused which is easy. Which CS440 do you have? The one that is clamshell like MOS posted or this one that shows bolt on cylinder and splitting crankcase?

Echo CS 440 EVL IPL

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Offline Cut4fun .

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Offline North West Farmer

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #6 on: November 19, 2011, 11:20:00 am »
brokenbudget,

I believe the top end cylinder is o.k..  We have shined a bright light into the cylinder and have felt the surfaces.  As far as we can determine the top end all right.  When you see the condition of the piston and the condition of the top end, it is difficult to believe they came from the same saw.

Fortunately, when attempting to start the saw it must have only made it over a time or two.  There was a bunch of broken debris on top of the piston and some very small particulate material in the bottom of the crank case, but apparently the junk went up and down and didn't drag or cause abrasion to the cylinder walls. 

By sending some pictures to you folks, that are more in the know about chainsaw inner workings, there may be something noticed that I am not picking up on. 

Definitely don't want to put this great little saw back together without getting a real good look and the bottom end in total.  I already feel bad enough after loosing the lock washer down the intake.

The real catcher for me is, how I somehow lost the lock washer down the intake when I found the accompanying standard washer on the work bench below the location where the work was being performed on the chainsaw.

This process did a dandy job of straightening out the lock washer.  It would have taken a bunch of work to accomplish the same thing yourself.

Could you explain what "Lock this topic" means?  I have looked through the forum directions and instructions and do not recall an explanation of "Lock this topic".

Thank you for the rapid reply and assistance.

Chainsawrepair,

I saw the question you posted while I was posting to brokenbudget.  My chainsaw is a different model than the on he posted.  Mine is the CS-440EVL that is one with the bolt on cylinder and the split crank case.  Mine is the older one.

Nick, North West Farmer

Offline North West Farmer

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #7 on: November 19, 2011, 11:25:07 am »
Chainsawrepair,

I don't know if I confused the post, but I combined my answer to you with another post.  To be clear, my saw is the older one, the CS-440EVL.  Bolt on cylinder and split case.

Nick, North West Farmer

Offline brokenbudget

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #8 on: November 19, 2011, 12:02:23 pm »
AAAAAAAAAAH the EVL! ;) gotcha! i was thinking the newer plastic version ;D still both good saws.
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Offline Cut4fun .

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Re: ECHO CS-440EVL: OOPS installing new intake adapter
« Reply #9 on: November 19, 2011, 12:13:35 pm »
Yep the cs440evl can be split. I dont think you will have to though.

 I had a dolmar 166 grenade when it hung a ring on a transfer on a alky racesaw. Check the bearings for play up and down movement. Take mix in squirt bottle and flush bearings good over and over. You can look at inner area. Then pour mix in crankcase and rotate crank around and around. This should flush all metal particles out.  When rotating pay attention for hard spots in bearings while turning.

To split if your really want too look at that IPL pic remove everything and make sure remove the crankcase bolts, all of them. ;)  I just use a rubber hammer to break the seal and then remove each side separately.
 Now I have never had your saw in my hands to know what will be different.

There is some husky splitting cases videos in the how to section in the ported area here.
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