1
CS-440
01-45A-00
0
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.
CONTENTS
page
1 SERVICE INFORMATION ............................. 2
1-1 Specification ............................................... 2
1-2 Technical data ............................................ 3
1-3 Torque limits ............................................... 4
1-4 Special repairing materials ......................... 5
1-5 Service limits .............................................. 6
1-6 Special tools ............................................... 7
2 EMISSION ADJUSTMENT GUIDE ............... 8
2-1 General adjusting rules .............................. 8
2-2 Presetting idle adjust screw, L mixture needle
and H mixture needle ........................................ 8
2-3 Adjusting carburetor ................................. 10
Reference No. 01-45A-00
ISSUED:
200604
2
SERVICE INFORMATION
CS-440
1 SERVICE INFORMATION
1-1 Specifications
Model
CS-440
Dimensions Length*
mm(in)
398 (15.67)
Width
mm(in)
252 (9.9)
Height
mm(in)
272 (10.7)
Dry weight*
Engine
kg(lb)
Type
Rotation
Displacement
cm3(in3)
Bore
Stroke
mm(in)
mm(in)
4.8 (10.6)
KIORITZ, air-cooled, two-stroke, single cylinder
Clockwise as viewed from the output end
45.0 (2.747)
43.0 (1.693)
31.0 (1.220)
Compression ratio
Carburetor
6.5
Type
Diaphragm horizontal-draft with auto-return choke
Model
Walbro WT-416C
Venturi size-Throttle bore mm(in)
Ignition
Type
13.5 - 15.85 (0.532 - 0.624)
CDI (Capacitor discharge ignition) system
with electronic timing advancer
Spark plug
Starter
BPM8Y (for CANADA version : RCJ6Y)
Type
Automatic rewind
Rope diameter x length
Fuel
mm(in)
3.5 x 1000 (0.14 x 39.4)
Type
Premixed two-stroke fuel
Mixture ratio
Gasoline
Minimum 89 octane gasoline
Two-stroke air cooled engine oil
ISO-L-EGD (ISO/CD13738), JASO FC
Tank capacity
Clutch
50 : 1 (2 %)
L (U.S.fl.oz.)
Type
0.45 (15.2)
Centrifugal, 3-shoe slide with 3-tension spring
Guide bar / Saw chain lubrication type
Oil
Tank capacity
Sprocket
Type
Automatic with volume adjuster
L (U.S.fl.oz.)
0.28 (9.5)
Spur
Number of teeth
Pitch
7
in
0.325
* Without guide bar and saw chain.
Cutting devices
Guide bar
Saw chain
Part No.
Called length
in
Gauge
in
16A0AD3366
18A0AD3372
20A0AD3378
16
18
20
0.050
Type
OREGON 33SL
Number of drive links
66
72
Pitch
in
0.325
Gauge
in
0.050
78
3
SERVICE INFORMATION
CS-440
1-2 Technical data
Engine
Idling speed
Wide open throttle speed*
Clutch engagement speed
Compression pressure
Ignition system
rpm
2300 - 3300
rpm
11500 - 13000
rpm
3500 - 4000
2
MPa (kgf/cm ) (psi)
1.00 (10.2) (145)
Spark plug gap
mm(in)
Minimum secondary voltage at 1500 rpm
kV
Primary coil resistance
Secondary coil resistance
Pole shoe air gaps
Ignition timing
at 800 rpm
at 3000 rpm
at 10000 rpm
Carburetor
Idle adjust screw initial setting
0.6 - 0.7 (0.024 - 0.028)
15
Ω
kΩ
140 - 180
1.9 - 2.3
mm (in)
°BTDC
0.3 - 0.4 (0.012 - 0.016)
16.0
°BTDC
°BTDC
19.0
33.0
turns in**
1 5/8
Test Pressure, minimum
MPa (kgf/cm 2) (psi)
Metering lever height
mm(in)
Chain oil discharge volume at 7000 r/ min
mL/min(U.S.fl.oz./min)
0.05 (0.5) (7.0)
1.65 (0.06) lower than diaphragm seat
Adjustable : 1.5 - 13 (0.05 - 0.40)
(Factory set 7 mL/min)
BTDC: Before top dead center.
* With 18 in. guide bar and saw chain.
**Set idle adjust screw to contact throttle plate before initial setting.
4
SERVICE INFORMATION
CS-440
1-3 Torque limits
Descriptions
Starter Starter pawl
system Starter drum
Starter case
Size
kgf•cm
N•m
in•lbf
M 5*
70 - 110
7 - 11
60 - 95
M5
30 - 45
3 - 4.5
26 - 40
M 5*
30 - 45
M8
200 - 240
M4
35 - 50
3.5 - 5
30 - 45
Ignition lead
M4
15 - 25
1.5 - 2.5
13 - 22
Ignition switch
M 14
15 - 30
1.5 - 3
Spark plug
M 14
150 - 170
M5
30 - 35
3 - 3.5
26 - 30
M5
30 - 45
3.0 - 4.5
26 - 40
Clutch hub
LM 10
300 - 400
30 - 40
260 - 350
Engine Crankcase
M 5*
70 - 110
7 - 11
60 - 95
Engine mount
M5
70 - 110
7 - 11
60 - 95
Muffler
M5
70 - 110
7 - 11
60 - 95
Cylinder cover
M5
25 - 45
2.5 - 4.5
22 - 40
M4
20 - 35
2.5 - 3.5
17 - 30
Oil tank
M 4*
30 - 40
3- 4
22 - 35
Front handle
M 5**
45 - 65
4.5 - 6.5
40 - 55
M5
M 5*
30 - 45
45 - 60
3 - 4.5
4.5 - 6
26 - 40
40 - 50
Sprocket guard
for fixing rear handle
M5
30 - 45
3.0 - 4.5
26 - 40
Handle lid
M 4**
10 - 20
1- 2
9 - 17
Brake lever (Hand guard)
M5
25 - 45
2.5 - 4.5
22 - 40
Brake lever weight
M4
14 - 26
1.4 - 2.6
12 - 23
Brake cover
M 4**
10 - 20
1- 2
9 - 17
Sprocket guard plate
M 4**
10 - 20
1- 2
9 - 17
Chain catcher
M5
30 - 45
3 - 4.5
Guide bar
M8
200 - 230
20 - 23
M3
6 - 10
0.6 - 1.0
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
Ignition Magneto rotor (Flywheel)
system Ignition coil
Carburetor
Fuel
system Intake bellows
Clutch
Others Auto-oiler
Rear handle assembly
muffler side
rear hadle side
Regular bolt, nut,
and screw
LM: Left-hand thread
3 - 4.5
20 - 24
13 - 26
15 - 17
*Apply special repairing materials (See next page)
26 - 40
175 - 210
130 - 150
26 - 40
175 - 200
** Tapping screw
5
SERVICE INFORMATION
CS-440
1-4 Special repairing materials
Material
Adhesive
Location
Ball bearing outer / crankcase
Remarks
Loctite #675 or equivalent
Stud bolt
Liquid gasket
Thread locking sealant
Handle cushions
Loctite #424, ThreeBond #1741 or equivalent
Crankcase seams
Loctite #515 or equivalent
Starter pawl / Starter case
Loctite #242, ThreeBond #1324 or equivalent
Rear handle assembly
Brake lever weight
Oil tank
Grease
Loctite #222, ThreeBond #1342 or equivalent
Loctite #595, ThreeBond #1212 or equivalent
Auto-oiler worm
Clutch needle bearing
Internal handle cushions
Lithium based grease
Rewind spring
Starter center shaft
Chain brake (metal contact part)
Molybdenum grease (approx. 1 gram)
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SERVICE INFORMATION
CS-440
1-5 Service Limits
A
5K280
B
5K282
F
E
5K285
5K016
K
L
C
D
5K283
5K284
G
H
5K042
5K281
M
P
N
5K173
5K174
5K171
5K191B
2
3
Description
A Cylinder bore
When plating is worn and aluminum can be seen
B Piston outer diameter
Min.
42.85 (1.687)
C Piston pin bore
D Piston ring groove
Max.
Max.
9.030 (0.3555)
1.3 (0.051)
E Piston ring side clearance
Max.
0.1 (0.004)
F Piston pin outer diameter
G Piston ring width
Min.
Min.
8.98 (0.3535)
1.15 (0.045)
H Piston ring end gap
Max.
K Con-rod small end bore
L Crankshaft runout
Max.
Max.
12.125 (0.4774)
0.05 (0.002)
0.5 (0.02)
M Sprocket bore
Max.
13.07 (0.5146)
N Clutch drum bore
Max.
71.5 (2.81)
P Sprocket wear limit
Max.
0.5 (0.02)
CS-440
SERVICE INFORMATION
7