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Echo Chain Saw CS590 2019 Ignition Assembly Replacement

Introduction

Use this guide to replace the ignition assembly in your Echo Chain Saw CS-590 (2019). The ignition assembly includes the ignition coil, flywheel, and the woodruff key.

Although it's not necessary to remove the guide bar, it's highly recommended you do so to minimize any damage to the chain and to yourself.

What you need

  1. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Turn off the chainsaw: step 1, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Turn off the chainsaw: step 1, image 2 of 2

    • Make sure you have the ignition switch turned off before starting your repair.

    • The chainsaw should be cool to the touch before continuing.

    Edit

  2. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Loosen the air filter cover: step 2, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Loosen the air filter cover: step 2, image 2 of 2

    • Use your fingers to loosen the air filter cover knob.

    Edit

  3. Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 3, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 3, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 3, image 3 of 3

    • Remove the air filter cover.

    Edit

  4. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Disconnect the spark plug: step 4, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Disconnect the spark plug: step 4, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Disconnect the spark plug: step 4, image 3 of 3

    • Use your fingers to pull up and disconnect the spark plug boot.

    Edit

  5. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the air filter: step 5, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the air filter: step 5, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the air filter: step 5, image 3 of 3

    • To minimize debris entering the intake, pull the choke shut before continuing.

    • Remove the air filter

    • During reassembly, clean the air filter with compressed air or with light brushing before reinstalling it.

    Edit

  6. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the front handle: step 6, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the front handle: step 6, image 2 of 2

    • Use a T25 Torx screwdriver to remove the five screws securing the front handle to the bottom and right side of the device:

    • Four 24 mm-long screws

    • One 25 mm-long screw

    Edit

  7. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the front handle: step 7, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the front handle: step 7, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the front handle: step 7, image 3 of 3

    • Pull the handle toward the rear of the device to remove it.

    Edit

  8. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the sprocket guard: step 8, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the sprocket guard: step 8, image 2 of 2

    • Use a 13 mm wrench to remove the two nuts securing the sprocket guard.

    Edit

  9. Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 9, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 9, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 9, image 3 of 3

    • Remove the sprocket guard.

    Edit

  10. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the guide bar: step 10, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the guide bar: step 10, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the guide bar: step 10, image 3 of 3

    • Push the guide bar towards the back of the device to create slack in the saw chain.

    • Pull the guide bar away from the device to separate the saw chain from the clutch drum.

    • Remove the guide bar.

    Edit

  12. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the front hand guard: step 11, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the front hand guard: step 11, image 2 of 2

    • Make sure the front hand guard is in the unlocked position before continuing.

    • Use a T25 Torx screwdriver to remove the two 20 mm screws securing the front hand guard.

    Edit

  13. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the front hand guard: step 12, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the front hand guard: step 12, image 2 of 2

    • Pull the front hand guard toward the rear of the device to remove it.

    Edit

  14. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the engine cover: step 13, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the engine cover: step 13, image 2 of 2

    • Use a T25 Torx screwdriver to remove the three 20 mm screws securing the engine cover.

    Edit

  15. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the engine cover: step 14, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the engine cover: step 14, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the engine cover: step 14, image 3 of 3

    • Pull the engine cover straight off the device to remove it.

    Edit

  16. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the starter case: step 15, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the starter case: step 15, image 2 of 2

    • Use a T25 Torx screwdriver to remove the four 24 mm screws securing the starter case.

    Edit

  17. Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 16, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 16, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 16, image 3 of 3

    • Remove the starter case.

    Edit

  18. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the spark plug cable: step 17, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the spark plug cable: step 17, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the spark plug cable: step 17, image 3 of 3

    • Use your fingers to reroute the spark plug cable from its slot in the fan cover.

    Edit

  19. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the ignition coil cable: step 18, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the ignition coil cable: step 18, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Reposition the ignition coil cable: step 18, image 3 of 3

    • Use your fingers to reroute the ignition coil cable from its slot in the fan cover.

    Edit

  20. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Disconnect the ignition coil: step 19, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Disconnect the ignition coil: step 19, image 2 of 2

    • Use pliers, or your fingers, to disconnect the ignition coil cable's spade connector.

    • Grip the connector by the base of the clear head and not the wire itself.

    Edit

  21. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the ignition coil: step 20, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the ignition coil: step 20, image 2 of 2

    • Use a T25 Torx screwdriver to remove the two 20 mm screws securing the ignition coil.

    • During reassembly, insert the ignition air gap gauge to ensure a 0.35 mm space between the coil and the magnet.

    Edit

  22. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the ignition coil: step 21, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the ignition coil: step 21, image 2 of 2

    • Remove the ignition coil.

    Edit

  23. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the flange nut: step 22, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the flange nut: step 22, image 2 of 2

    • Wedge a flathead screwdriver between the chassis and the flywheel's spokes to prevent the flywheel from spinning.

    • Alternatively, you can seize the piston by inserting a rope down the spark plug shaft.

    • Use a 13 mm wrench to loosen and remove the flange nut located in the middle of the flywheel.

    Edit

  24. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the starter pawls: step 23, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the starter pawls: step 23, image 2 of 2

    • Use a T25 Torx screwdriver to remove the two 16 mm screws securing the starter pawls.

    • Remove the starter pawls.

    Edit

  25. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Starter pawl assembly information: step 24, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Starter pawl assembly information: step 24, image 2 of 2

    • During reassembly, be sure to reinstall the starter pawl assembly top to bottom in the following order:

    • 16 mm screw

    • Washer

    • Starter Pawl

    • Spacer

    • Torsion Spring

    Edit

  26. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the flywheel: step 25, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Unfasten the flywheel: step 25, image 2 of 2

    • Use a flywheel puller to disconnect the flywheel from the woodruff key.

    Edit

  27. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the flywheel: step 26, image 1 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the flywheel: step 26, image 2 of 3 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the flywheel: step 26, image 3 of 3

    • Pull the flywheel straight off of the crankshaft and remove it.

    Edit

  28. Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the woodruff key: step 27, image 1 of 2 Echo Chain Saw CS590 2019 Ignition Assembly Replacement, Remove the woodruff key: step 27, image 2 of 2

    • Insert a flathead screwdriver into the gap at the top of the woodruff key.

    • Pry with the screwdriver to separate the key from the crankshaft.

    Edit

  29. Echo Chain Saw CS590 2019 Ignition Assembly Replacement: step 28, image 1 of 1

    • Use pliers, or your fingers, to remove the woodruff key.

    • During reassembly, be sure to reinsert the woodruff key with the flat side facing outward.

    Edit
Conclusion

To reassemble your device, follow these instructions in reverse order.

One other person completed this guide.

Author

Alex Diaz-Kokaisl

Member since: 01/16/22

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