How to Replace the Chain Brake on an Echo Chainsaw

The chain brake attaches to the saw over the clutch drum. The brake has a metal band that wraps around the drum. When the handguard is pushed forward, the brake is engaged, which tightens the metal band around the drum, bringing the chain to a quick stop. The chain brake kit consists of the brake band, the spring and linkage, and the plastic housing.

Let's get started.

REMOVING THE CHAIN BRAKE   1. Remove the chain brake.

a. Use a wrench to loosen the two bar nuts.

b. Use a screwdriver to rotate the chain adjustment screw counterclockwise to reduce tension from the chain.

c. Remove the two bar nuts.

d. Remove the chain brake assembly from the saw.

  2. Remove the bar and chain.

a. Carefully remove the chain from the front of the bar.

b. Remove the chain from the rear sprocket.

c. Remove the bar from the saw.

  3. Remove the tensioner assembly.

a. Lay the chain brake assembly on your workbench so that the metal brake band faces up.

b. Remove the two screws securing the metal cover plate to the tensioner assembly.

c. Remove the metal cover plate.

d. Remove the chain tensioner assembly (bolt, collar, bevel gear, and pin) from the brake housing.

e. Remove the second (slotted) bevel gear from the brake housing. This can be done by simply inverting the housing on your workbench (and the gear should fall out freely).

INSTALLING THE NEW CHAIN BRAKE

  4. Install the tensioner assembly.

a. Install the (slotted) bevel gear into the new chain brake housing.

b. Use a small screwdriver (as necessary) to seat the gear in the channel on the new housing.

c. Install the tensioner assembly (bolt, collar, bevel gear, and pin) into the new chain brake housing. The plastic collar should fit snugly into the channel on the housing and the tensioner pin should face away from the workbench.

d. Install the metal cover plate onto the new chain brake housing.

e. Secure the metal cover plate with the two screws.

REASSEMBLING THE UNIT

  5. Reinstall the bar and chain.

a. Install the bar onto the bar studs.

b. Slide the bar toward the rear of the saw.

c. Carefully install the rear portion of the chain around the sprocket and drum.

d. Install the front portion of the chain onto the bar, ensuring that the chain aligns with the groove along the top of the bar, as well as the sprocket at the tip of the bar.

e. Slide the bar toward the front of the saw until the chain seats snugly onto the bar.

  6. Reinstall the chain brake assembly.

a. Install the chain brake assembly onto the saw (the bar studs should align with the openings on the housing).

b. Use a screwdriver to rotate the tensioner screw (as-needed) until the chain tensioner pin engages with the slot on the bar.

c. Install (but do not fully tighten) the bar nuts onto the bar studs.

  7. Tension the chain.

a. Grasp and raise the distant end of the bar and chain assembly (opposite the engine).

b. While holding the bar in a raised position, use a screwdriver to rotate the tensioner screw until the chain begins to tighten against the bar.

c. Lift the chain away from the bar assembly and inspect the gap between the two components.

d. The chain is tensioned correctly when you are able to raise the chain slightly away from the bar without creating a visible gap between the guide links and the top of the bar.

e. Once the chain is properly adjusted, tighten the bar nuts to secure the assembly.