Husqvarna W9600001 Repair Manuals

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Husqvarna Chain Saws

Workshop Manual

101 88 55-26

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LIST OF CONTENTS

Introduction ..................................... 3

Safety regulations ........................... 5

Technical Data ................................. 6

Tools............................................... 14

Service data ................................... 20

Trouble shooting ........................... 40

Safety equipment .......................... 42

Starter............................................. 57

Electrical system........................... 61

Centrifugal clutch.......................... 67

Lubrication system ....................... 70

Carburettor..................................... 83

Air filter ........................................ 101

Tank unit....................................... 103

Anti-vibration system.................. 106

Piston cylinder............................. 108

Crankcase and crankshaft.......... 114

2 – English

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INTRODUCTION

General Updates

This workshop manual provides a detailed description of procedures for trouble shooting, repair and testing of the chain saws. Safety precautions that should be taken during repair are also described.

This workshop manual applies to the engine assembly in the following chain saws:

36 40

257 262XP

268 41 42

272XP

268K 45 51

272K

272S 55 61

281XP

288XP 242XP 246 254XP

394XP

3120XP

As production continues, changes will be introduced successively to the chain saw. If at any time these changes influence service and/or spares, special service announcements will be sent out, which means that this manual will cease to be current with time. In order to avoid problems, the manual should always be read together with all service announcements that apply to the specific model of chain saw.

Tools

For specific procedures special tools are required. In this workshop manual, all the service tools required are listed. Use of the tools is described in appropriate sections.

Always use Husqvarna original:

• Spare parts

• Service tools

• Accessories

Safety

Note! The section dealing with safety should be read and understood by all who carry out repair or service work on the chain saw.

There are warning symbols on the chain saw. If a warning symbol has been damaged or is missing, it must be replaced immediately in order to maximise safety when the saw is in use.

Target group

This workshop manual is written for personnel that are assumed to have general knowledge of service and repair of small engines.

The workshop manual should be read and understood by all personnel carrying out service and repair work on the chain saw. The manual is also suitable for use in the training of new employees.

Layout

The descriptive sections in this workshop manual are set out in a number of flow diagrams. When carrying out repairs on a specific chain saw, follow the signs that apply to the saw in question.

Diagrams are not numbered as they are linked to the actual text, either by lines or by being in the same box.

Positional directives to components inside the diagrams are designated with A, B, etc. and start from A again in each new section.

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INTRODUCTION

Use

This workshop manual can be used in two different ways:

• Repair of a specific sub-assembly

• Dismantling and reassembly of the entire chain saw

Repair of a specific sub-assembly

When a specific sub-assembly on the chain saw is to be repaired, proceed as follows:

1. Refer to the page referring to the relevant subassembly.

2. Carry out the steps: Dismantling

Cleaning and inspection Reassembly

Dismantling and reassembly of the entire chain saw

When the entire chain saw is to be dismantled and reassembled, proceed as follows:

1. Refer to page 57, which deals with the Starter and carry out the instructions under the heading Dismantling.

2. Work forwards through the manual and carry out Dismantling instructions in the order that the sections occur.

3. Return to the Starter on page 58 and follow the instructions under Cleaning and Inspection.

4. Work forward through the manual and carry out Cleaning and Inspection in the order that the sections occur.

5. Order or collect all the required spare parts from the spare parts stores.

6. In order to Assemble the chain saw, proceed as follows:

• Refer to pages 117-120 which deals with the Crankcase and carry out the instructions under Assembly.

• Refer to pages 111-112 which deals with the Piston and Cylinder and carry out the instructions under Assembly.

• Refer to pages 107 which deals with the Anti-vibration system and carry out the instructions under Assembly.

• Refer to page 105 which deals with the Tank unit and carry out the instructions under Assembly.

Continue to work backwards through the manual and carry out Assembly instructions as the sections occur.

In order to improve understanding, some sections begin with a Description of the relevant sub-assembly.

4 – English

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SAFETY REGULATIONS

General Instructions

Workshops where chain saws are serviced must be equipped with safety equipment as set out in local directives.

No one should repair a chain saw without first having read and understood the contents of this workshop manual.

The following warning texts are to be found in this manual in certain places. The warning texts occur before the procedure to which they refer.

WARNING!

The warning text indicates a risk of personal injury if instructions are not followed.

Special instructions

The fuel used in the chain saw poses the following hazards:

1. The fluid and its fumes are poisonous.

2. Can cause eye and skin irritation.

3. Can cause breathing difficulties

4. Is highly inflammable. The bar, chain and clutch cover (chain

brake) must be assembled before the chain saw is started, otherwise the clutch may come loose causing personal injury.

Wear ear muffs when testing the chain saw.

Do not use the saw until it has been adjusted so that the chain does not rotate when idling.

Bear in mind the fire risk. The saw can produce sparks that can cause a fire hazard..

NOTE! The warning text indicates a risk of damage to equipment if instructions are not followed.

The chain saw is type approved with regard to safety according to applicable legal requirements when fitted with the cutting equipment specified in the Operator's Manual. Equipping the saw with other equipment or accessories and spare parts not approved by Husqvarna can result in non compliance with these safety requirements and liability for persons carrying out such modifications.

After testing, do not touch the silencer until it has cooled. Risk

the saw is fitted with a catalytic converter. The coating on and in the catalytic element is hazardous to touch. Use protective gloves when working on the catalytic converter.

Inadequate chain lubrication can result in the chain breaking, which can cause serious or fatal injury.

tension before the cord pulley is removed.

tension, otherwise the spring can fly out causing personal injury.

After repair, the chain brake must be checked in accordance with the instructions on page 47.

of burns. This especially applies if

Make sure that the starter recoil spring does not fly out and cause personal injury. Release the spring

When removing the pressure spring for the chain brake, ensure that the brake is in the 'on' position which reduces the spring

When replacing the crankshaft bearings note that the crankcase halves are hot. Use protective gloves.

When using compressed air, the air jet should never be pointed towards the body. Air can be forced into the blood stream, which can cause fatality.

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TECHNICAL DATA

Displacement Bore Stroke Max. power at

36 36 38.0 32.0 9000 40 40 40.0 32.0 9000 41 40 40.0 32.0 9000

42 42 42.0 30.0 9300 45 44 42.0 32.0 9000 51 51 45.0 32.0 9000

mm mm r/min

Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches

36 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239 40 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1 41 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239

42 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98 45 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1 51 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170

Bar length Chain speed Chain pitch Drive link gauge

cm/inches m/s inches mm/inches

36 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050 40 33-46/13-18 17.4/8500 rpm .325 1.3/ .050 41 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050

42 28-46/11-18 17.9/9300 rpm .325 1.5/ .058 / 1.3/ .050 45 33-46/13-18 17.4/8500 rpm .325 1.3/ .050 51 33-51/13-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050

From May 1996

6 – English

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TECHNICAL DATA

Idling speed Engagement speed Max. speed Spark plug

r/min r/min r/min Champion

36 3000 4500 13000 RCJ 7 Y 40 2500 3600 12500 RCJ 7 Y 41 3000 4500 13000 RCJ 7 Y

42 2700 3800 14500 RCJ 7 Y 45 2500 3600 12500 RCJ 7 Y 51 2500 3700 12500 RCJ 7 Y

Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump

Litres cm

36 0.4 7 0.2 Yes 40 0.5 8 0.25 Yes 41 0.4 7 0.2 Yes

42 0.5 3-7 0.27 Yes 45 0.5 8 0.25 Yes 51 0.6 10 0.3 Yes

Weight without bar and chain Weight with bar and chain Handle heater

kg kg/lbs Watt/ r/min

36 4.6 5.3 (13") No 40 4.7 5.4 (13") No 41 4.6 5.3 (13") No

/min at 8.500 rpm Litres

42 4.7 5.5 (13") No 45 4.7 5.4 (13") No 51 5.2 6.2 (15") No

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TECHNICAL DATA

Displacement Bore Stroke Max. power at

55 53 46.0 32.0 9000 61 62 48.0 34.0 8300 242XP 42 42.0 30.0 9900

246 46 44.0 30.0 9000 254XP 54 45.0 34.0 9300 257 57 46.0 34.0 9000

mm mm r/min

Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches

55 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170 61 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 254 242XP 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98

246 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98 254XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 35B 257 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120

Bar length Chain speed Chain pitch Drive link gauge

cm/inches m/s inches mm/inches

55 38-51/15-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050 61 38-51/15-20 18.4/8300 rpm 3/8 1.5/ .058 242XP 28-46/11-18 19.1/9900 rpm .325 1.5/ .058 / 1.3/ .050

246 28-46/11-18 17.3/9000 rpm .325 1.5/ .058 / 1.3/ .050 254XP 33-51/13-20 17.3/9300 rpm .325-3/8 1.5/ .058 257 33-51/13-20 17.3/9000 rpm .325-3/8 1.5/ .058

1) From May 1996

8 – English

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TECHNICAL DATA

Idling speed Engagement speed Max. speed Spark plug

r/min r/min r/min Champion

55 2500 3700 12500 RCJ 7 Y 61 2500 3700 12000 RCJ 7 Y 242XP 2700 3900 15500 RCJ 7 Y

246 2700 3900 15000 RCJ 7 Y 254XP 2700 3700 13800 RCJ 7 Y 257 2700 3700 13500 RCJ 7 Y

Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump

Litres cm

55 0.6 10 0.3 Yes 61 0.75 4/8/12/17 0.45 Yes 242XP 0.5 3-7 0.27 Yes

246 0.5 3-7 0.27 Yes 254XP 0.6 3-10 0.3 Yes 257 0.6 3-10 0.3 Yes

Weight without bar and chain Weight with bar and chain Handle heater

kg kg/lbs Watt/ r/min

55 5.2 6.2 (15") No 61 6.1 7.1 (15") No 242XP 4.7 5.5 (13") 65/10.000

/min at 8.500 rpm Litres

246 4.7 5.5 (13") No 254XP 5.4 6.3 (13") 65/10000 257 5.6 6.6 (13") 65/10000

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TECHNICAL DATA

Displacemennt Bore Stroke Max. power at

262XP 62 48.0 34.0 9600 268 67 50.0 34.0 9000 272XP 72 52.0 34.0 9300

268K 67 50.0 34.0 9000 272K 72 52.0 34.0 9300 272S 72 52.0 34.0 9300

mm mm r/min

Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches

262XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120 268 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260 272XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260

268K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255 272K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255 272S 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255

Bar length Chain speed Chain pitch Drive link gauge

cm/inches m/s inches mm/inches

262XP 33-51/13-20 18.5/9600 rpm .325-3/8 1.5/ .058 268 38-51/15-20 18.4/9000 rpm 3/8 1.5/ .058 272XP 38-51/15-20 20.0/9300 rpm 3/8 1.5/ .058

268K - - - 272K - - - 272S - - - -

10 – English

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TECHNICAL DATA

Idling speed Engagement speed Max. speed Spark plug

r/min r/min r/min Champion

262XP 2700 3400 13500 RCJ 7 Y 268 2500 3500 12500 RCJ 7 Y 272XP 2500 3500 13500 RCJ 7 Y

268K 2500 3500 10000 RCJ 7 Y 272K 2500 3500 10000 RCJ 7 Y 272S 2500 3500 10000 RCJ 7 Y

Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump

Litres cm

262XP 0.6 6.5-13.5 0.3 Yes 268 0.75 4/9/13/17 0.45 Yes 272XP 0.75 5/9/14/19 0.45 Yes

268K 0.75 - - 272K 0.75 - - 272S 0.75 - - -

Weight without chain and bar Weight with chain and bar Handle heater

kg kg/lbs Watt/ r/min

262XP 5.8 6.8 (13") 65/10000 268 6.2 7.2 (15") 65/10000 272XP 6.3 7.3 (15") 65/10000

/min at 8.500 rpm Litres

268K 9.5 - 272K 9.6 - 272S 21.0 (including carriage) - -

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TECHNICAL DATA

Displacement Bore Stroke Max. power at

281XP 81 52.0 38.0 9000 288XP 87 54.0 38.0 9300

394XP 94 56.0 38.0 8800 3120XP 119 60.0 42.0 9000

mm mm r/min

Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches

281XP 0.5/ .02 SEM AM 7 0.3/ .012 TILLOTSON HS 228 288XP 0.5/ .02 SEM AM 7 0.3/ .012 TILLOTSON HS 228

394XP 0.5/ .02 SEM AM 44 0.3/ .012 WALBRO WJ 39 3120XP 0.5/ .02 SEM AM 37 0.3/ .012 WALBRO WG 6

Bar length Chain speed Chain pitch Drive link gauge

cm/inches m/s inches mm/inches

281XP 38-71/15-28 20.0/9000 rpm 3/8 1.5/ .058 288XP 38-71/15-28 20.7/9300 rpm 3/8 1.5/ .058

394XP 46-91/18-36 19.6/8800 rpm 3/8-.404 1.5/ .058 - 1.6/.063 3120XP 60-107/24-42 20.1/9000 rpm .404 1.6/ .063

12 – English

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TECHNICAL DATA

Idling speed Engagement speed Max. speed Spark plug

r/min r/min r/min Champion

281XP 2500 3200 12500 RCJ 6 Y 288XP 2500 3200 12500 RCJ 6 Y

394XP 2500 3400 12500 RCJ 6 Y 3120XP 2500 3300 11500-12500 RCJ 7 Y

Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump

Litres cm

281XP 0.9 9/12/15/18 0.5 Yes 288XP 0.9 9/12/15/18 0.5 Yes

394XP 0.9 14-21 0.5 Yes 3120XP 1.25 8-51 0.7 Yes

Weight without bar and chain Weight with bar chain Handle heater

kg kg/lbs Watt/ r/min

281XP 7.5 8.7 (18") 56/7200 288XP 7.5 8.7 (18") 56/7200

/min at 8.500 rpm Litres

394XP 7.9 9.2 (18") 65/10000 3120XP 10.4 12.3 (28") No

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TOOLS

Tools for all chain saws

502 50 57-01 3/16" 502 50 16-01 6 mm 502 50 64-01 5 mm 502 50 18-01 4 mm 502 50 19-01 3 mm

502 50 88-01 5 mm 502 50 87-01 4 mm 502 50 86-01 3 mm

502 71 13-01

502 50 22-01 8 mm 502 50 23-01 10 mm

502 51 34-02 (0,3 mm)

compl 502 50 70-01

502 51 91-01 (0,5 mm)

502 50 06-01

502 50 37-01

502 70 09-01

504 98 26-01 (36, 41, 40, 45)

502 50 83-01

14 – English

502 51 02-01

502 71 14-01

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TOOLS

Tools for saws 36 and 41 Tools for saws 40, 45, 51 and 55

3 mm; 4 mm; 5 mm 8 mm; 10 mm

530 03 11-12

502 51 94-01

502 51 00-02

502 50 33-01

530 03 11-36

4 mm 8 mm

40 > 910 1116 45 > 925 1168 50 > 925 0856

502 50 99-01 (55)

502 51 61-01 (51, 55)

505 26 79-12

502 50 33-01

502 50 26-01 (55)

502 51 94-01

505 38 18-17 (40. 45)

504 90 90-01

502 50 30-09 40 > 910 1116 45 > 925 1168

504 90 29-02

502 50 79-01 (55)

compl 502 50 38-01

502 54 03-01 (40, 45, 55)

502 50 46-01 (55)

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TOOLS

Tools for saws 42, 242 and 246 Tools for saws 254, 257 and 262

3 mm; 4 mm 8 mm

*compl 502 51 49-02

502 50 26-01*

502 70 03-01

502 50 33-01

502 51 49-01*

*502 51 54-01

502 50 99-01

3 mm; 4 mm 8 mm

502 50 33-01

*compl 502 51 49-02

502 51 49-01*

*502 51 54-01

502 50 26-01*

502 50 99-01

compl 502 50 31-01

502 50 82-01

502 51 32-01

502 50 72-01

502 50 71-01

502 51 61-01

502 50 30-07

502 51 50-01

502 51 00-02

compl 502 50 38-01

504 90 90-01

502 50 45-01

502 50 46-01

502 51 61-01

502 50 79-01

502 50 72-01

502 50 71-01

504 90 90-01

502 50 30-10

compl 502 50 38-01

502 50 45-01

502 50 46-01

16 – English

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TOOLS

Tools for saws 61, 268 and 272

3 mm; 4 mm; 3/16" 8 mm

502 50 33-01

*compl 502 51 49-02 *compl 502 51 49-02

502 51 49-01*

502 50 26-01*

502 70 03-01

502 71 36-01 (4 mm)

*502 51 54-01

Tools for saws 281 and 288

3 mm; 4 mm; 3/16"

8 mm

502 51 49-01*

502 71 36-01 (4 mm)

502 50 33-01

*502 51 54-01

502 50 26-01*

compl 502 50 31-01

502 51 69-01 (268)

502 50 47-01

502 50 48-01

502 51 61-01

502 50 53-01 502 50 52-01

502 50 66-02 502 50 67-01 502 51 00-02

compl 502 50 38-01

504 90 90-01

502 50 30-04

502 50 45-01

502 50 46-01

502 51 61-01

502 50 82-01

502 50 66-02

compl 502 50 38-01

502 50 47-01

502 50 81-01

504 90 90-01

502 50 30-08

502 50 46-01

502 50 20-01

English – 17

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TOOLS

Tools for saws 394 and 3120

3 mm; 4 mm; 5 mm; 3/16" 8 mm; 10 mm

502 50 33-01

*compl 502 51 49-02

502 51 49-01*

*502 51 54-01

502 50 82-01

502 50 52-01

502 50 26-01*

504 90 90-01

502 50 30-08

502 50 66-02

compl 502 50 38-01

502 52 01-01 (394) 502 71 38-01 (3120)

502 71 39-01 (394)

18 – English

502 52 04-01 (394) 502 71 40-01 (3120)

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TOOLS

List of tools

Order number Designation 502 50 06-01 Pliers

502 50 16-01 Allen key 502 50 18-01 Allen key 502 50 19-01 Allen key 502 50 20-01 Assembly tool

502 50 22-01 Socket 502 50 23-01 Socket 502 50 26-01 Puller 502 50 30-04 Assembly tool 502 50 30-08 Assembly tool

502 50 30-09 Assembly tool 502 50 30-10 Assembly tool 502 50 31-01 Puller 502 50 33-01 Piston stop 502 50 37-01 Vacuum gauge

502 50 38-01 Pressure gauge 502 50 45-01 Extended socket 502 50 46-01 Extended socket 502 50 47-01 Cover plate 502 50 48-01 Cover plate

Order number Designation

502 51 49-01 Puller 502 51 49-02 Puller 502 51 50-01 Socket 502 51 54-01 Bolt set 502 51 61-01 Dismantling tool, crankcase

502 51 69-01 Assembly mandrel 502 51 69-01 Feeler gauges

502 51 94-01 Assembly mandrel

502 52 01-01 Cover plate 502 52 04-01 Spacer

502 54 03-01 Spacer 502 70 09-01 Pump blower 502 71 13-01 Test spark plug 502 71 14-01 Tachometer 502 71 36-01 Allen key

502 71 38-01 Cover plate 502 71 39-01 Cover plate 502 71 40-01 Spacer 504 90 29-02 Cover plate 504 90 90-01 Puller

502 50 52-01 Assembly socket 502 50 57-01 Allen key 502 50 64-01 Allen key 502 50 66-02 U-key 502 50 67-01 U-key

502 50 70-01 Assembly tool, piston 502 50 71-01 Cover plate 502 50 72-01 Cover plate 502 50 79-01 Assembly mandrel 502 50 81-01 Cover plate

502 50 82-01 Assembly mandrel 502 50 83-01 Hook, tank valve 502 50 86-01 Allen key 502 50 87-01 Allen key 502 50 88-01 Allen key

502 50 99-01 Puller sleeve 502 51 00-02 U-key 502 51 02-01 Assembly fixture 502 51 32-01 Assembly sleeve 502 51 34-02 Feeler gauge

504 98 26-01 Silicone rubber 505 26 79-12 Assembly mandrel 505 38 18-17 Puller

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SERVICE DATA

Saws 36 and 41

●

● ▲

●

■

▲

●

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

20 – English

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SERVICE DATA

▲

●

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English – 21

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SERVICE DATA

●

Saws 42, 242 and 246

8-10

7-8

242

4-5

42 246

242

●

● ▲

▲

■

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

22 – English

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●

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SERVICE DATA

▲

●

English – 23

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SERVICE DATA

3-4

●

2-3

25-35

Saws 40 and 45

7-8

●

■

●

2-3

▲

●

2-3

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

24 – English

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2-3

10-12

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SERVICE DATA

2-3

3-4

2-3

▲

3-4

25-30

2-3

8-10

2-3

●

2-3

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SERVICE DATA

4-5

●

Saws 51 and 55

7-8

30-40

6-8

■ ▲

▲

●

3-4

●

8-10

1,5-2

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

26 – English

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3-4

●

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SERVICE DATA

3-4

8-10

12-14

▲

1-2

3-5

●

3-4

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3-4

English – 27

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SERVICE DATA

●

Saws 254 and 257

254

257

●

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

■

●

▲

●

28 – English

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SERVICE DATA

▲

254

●

English – 29

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SERVICE DATA

●

Saw 262

●

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

■

●

▲

●

30 – English

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SERVICE DATA

▲

●

English – 31

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SERVICE DATA

●

Saws 61, 268 and 272

268 272

●

■

●

▲

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

32 – English

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●

Page 33

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SERVICE DATA

268 272

272

▲

●

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English – 33

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SERVICE DATA

●

Saws 281 and 288

●

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

■

●

▲

●

34 – English

●

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SERVICE DATA

▲

●

English – 35

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SERVICE DATA

●

Saw 394

10-12

6-8

●

2-4

■

●

7-9

●

▲

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

36 – English

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●

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SERVICE DATA

5-6

10-12

20-22,5

12-14

▲

3-5

▲

3-5

5-6

2-3

●

4-5

30-40

English – 37

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SERVICE DATA

●

Saw 3120

●

Character key

Numbers by components that are bolted refer to the tightening torque in Nm.

▲ = Lubricate using two-stroke oil.

■ = Lubricate using saw chain oil.

● = Lubricate using grease.

= Locking fluid (Loctite).

▲

■ ▲

●

38 – English

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SERVICE DATA

▲

●

English – 39

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TROUBLE SHOOTING

Trouble shooting schematic

Faults that can develop on the chain saw are divided into four groups as follows. In each category, possible malfunctions are shown on the left, with a list of possible faults on the right. The most probable fault is given first and so on.

Starting

Difficult starting

Carburettor leaking fuel

Flooding when the engine is not running

Adjust L-screw Air filter blocked Choke not working correctly Worn choke shaft Worn choke plate Fuel filter blocked Fuel line blocked Piston ring seized Blocked impulse channel

Loose or faulty fuel pipe Hole in diaphragm Worn needle valve/needle Control system sticking Control system set too high Leak in control system (air or fuel) Loose cover on carburettor pump side

Worn needle valve Control system set too high Control system sticking

Idling (low rpm) (cont.)

Idles when L-screw closed

Idling uneven

Worn needle valve/needle Leaking control diaphragm/ cover plate Control system sticking Worn throttle lever Faulty diffuser jet

Fuel filter blocked Fuel line blocked Leaking manifold Loose carburettor mounting Worn throttle valve shaft Loose throttle valve screw Worn throttle valve Control system sticking Leak in throttle system (air or fuel) Control diaphragm centre knob is worn Hole in diaphragm Leaking control diaphragm/ cover plate Crankcase leaking

Idling (low rpm)

Will not idle

Idling too rich

Adjust L-screw Leaking manifold (intermediate) Loose carburettor mounting Loose or faulty fuel pipe Fuel filter blocked Fuel line blocked Fuel tank breather blocked Throttle shaft and lever stiff Throttle cable sticking Defective throttle return spring Bent throttle lever shaft stop Faulty diffuser jet

Adjust L-screw Worn needle valve/needle Control system set too high Worn throttle lever Leaking control diaphragm/ cover plate Control system sticking

L-screw requires constant adjustment

Too much fuel at idling

Fuel line blocked Control system set too high Control system sticking Control system (air or fuel) Leaking control diaphragm/ cover plate Faulty diffuser jet Crankcase leaking

Control system set too high Control system sticking Control system damaged Worn needle valve Leaking control diaphragm/ cover plate Control system incorrectly assembled

40 – English

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TROUBLE SHOOTING

High rpm

Will not run at full throttle

Low power

Will not ”four-stroke”

Adjust H-screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting Control system set too low Control system damaged Control system incorrectly assembled Leaking control diaphragm/cover Control system sticking Blocked silencer

Adjust H-screw Blocked fuel tankbreather Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Control system sticking Leak in throttle system (air or fuel) Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm/cover Blocked fuel tank breather Blocked fuel filter

Fuel line blocked Loose or damaged fuel line Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting bolts Control system set too low Leak in throttle system (air or fuel) Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm/cover

Acceleration and retardation

Does not accelerate

Motor stalls when throttle released

Over rich acceleration

Adjust L-screw Adjust H-screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting Throttle set too low Control system incorrectly assembled Control system sticking Faulty diffuser jet Blocked silencer

Adjust L-screw Adjust H-screw Faulty pump diaphragm Control system set too high Control system sticking Faulty diffuser jet

Adjust L-screw Adjust H-screw Blocked air filter Faulty pump diaphragm Faulty diffuser jet

Trouble shooting methods

In addition to faults given in the above schematic, trouble shooting can be carried out on a specific component or sub-system of the chain saw. The different testing procedures are described in respective sections and are as follows:

1. Pressure testing the carburettor. See page 100.

2. Pressure testing the crankcase and cylinder. See page 114.

3. Pressure testing the decompression valve. See page 114.

4. Checking the operation of the chain brake. See page 47.

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SAFETY EQUIPMENT

Chain brake

Dismantling

Dismantle the clutch cover and clean. See the operating instructions.

Slide the hand guard forwards so that the brake is actuated.

Loosen the screw on the hand guard and screw back 2 turns. Gently hit the screw so that the threaded part of the bushing can be removed. Dismantle the other part of the bushing by means of a punch. Remove the cylindrical pin A.

All saws except 3120

Remove the cover on the chain brake spring. The cover has 4 or 5 screws.

3120

WARNING!

Place the clutch cover in a vice with the jaws positioned as shown below and release the tubular pin B. Carefully knock out the tubular pin B.

If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in personal injury! Wear protective glasses!

42 – English

WARNING! If the brake is not 'on', the spring can fly out resulting in personal injury. Wear protective glasses!

Continues on next page.

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3120 continues on next page.

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SAFETY EQUIPMENT

All saws except 3120

Slide up the back edge of the spring with a screwdriver.

Use a punch to knock out the pin holding the knee link.

3120

Carefully unscrew the vice so that the pressure rod and the ratchet move out of the clutch cover.

Dismantle the pressure rod from the brake band.

36, 41, 61, 268, 272, 281 and 288

Lift up the band's fixed end using a screwdriver and remove the loose parts.

40, 42, 45, 51, 242, 246, 55, 254, 257, 262 and 394

Remove the screw that holds the fixed end of the band.

Knock out the band's fixed end using a punch through the hole in the clutch cover and remove the loose parts.

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English – 43

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SAFETY EQUIPMENT

Cleaning and Inspection

Clean and inspect all parts. The thickness of the brake band must not be under 0.8 mm at any point.

Min. 0.8 mm

Assembly

Fit the band's fixed end into position on the clutch cover.

All saws except 3120

Grease the knee link and knock in the tubular pin that holds the knee link.

3120

Fit the screw that holds the band's fixed end.

44 – English

Continues on next page.

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3120 continues on next page.

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SAFETY EQUIPMENT

All saws except 3120

Slide the spring over the knee link's stud and press down the opposite end of the spring into its recess.

3120

Fit the spring and screw onto the pressure rod on the brake band. Note! Plastic sleeve. Bottom the screw onto the pressure rod thread and back off 4-5 turns.

Fit the cover over the spring.

Continues on next page.

WARNING!

Grease and fit the ratchet. Set the unit in a vice, positioned in the jaws as shown below.

If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in personal injury!

3120 continues on next page.

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English – 45

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SAFETY EQUIPMENT

All saws except 3120

Fit the hand guard, the two bushings and the screw.

3120

Carefully tighten the vice until the hole for the tubular pin and the ratchet align.

Fit the cylindrical pin.

Carefully knock in the pin.

Pull back the hand guard so that the brake is not actuated.

46 – English

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Check the chain brake as described on the next page.

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SAFETY EQUIPMENT

Checking brake operation

WARNING!

The engine should not be running during the test.

Test that the chain brake comes on as follows:

After repair, the chain brake must be checked as set out in the following instructions.

Hold the chain saw above a firm surface. The distance between the bar and the surface are shown in the table below.

Bar length, L Height, H

15-20 inches 50 cm 21-28 inches 70 cm 29-32 inches 80 cm

Release the front handle and let the chain saw rotate around the rear handle.

When the bar nose hits the surface the chain brake should trip.

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English – 47

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SAFETY EQUIPMENT

Chain catcher

Description

The chain catcher is intented to catch the chain if it should break. The chain catcher has a different design and is secured differently on the chain saws described in this manual.

The following designs are used:

• Aluminium angle.

• Plastic angle.

• Fixed roller.

• Rotating roller. The following securing methods are used:

• Using screws on the crankcase.

• Using screws on the spike.

• Using nuts on the spike.

Replacing

Dismantle the chain and bar. See the operating instructions

Check the chain catcher and replace if broken or badly damaged. The tightening torque is stated in the service data

Reassemble the chain and bar. See the operating instructions

48 – English

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SAFETY EQUIPMENT

Muffler

Dismantling

WARNING!

If the saw is equipped with muffler mounting (A), unscrew this from the crankcase and muffler.

Unscrew the muffler from the cylinder (M5 or M6 bolts, M5 or M6 nuts).

Remove the muffler, gasket and cooling plate (B) if the saw is so equipped.

Do not touch the muffler until it has cooled. Risk of burns!

If the saw is equipped with a spark arrester (C), remove this.

Saw 242 Cat

WARNING!

The coating on and in the catalytic converter element (A) is hazardous to your health if touched. Wear protective gloves when working on a catalytic converter

Dismantle the muffler as shown in the figure to the right.

Saws 36 and 41

Dismantle the muffler as shown in the figure to the right.

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SAFETY EQUIPMENT

Cleaning and Inspection

WARNING!

The coating on and in the catalytic converter element (A) is hazardous to your health if touched. Wear protective gloves when working on a catalytic converter

Assembly

Clean all contact surfaces.

Other saws

If the saw is equipped with a spark arrester (C), fit this.

Fit the cooling plate (B) if fitted, gasket and muffler on the cylinder.

Saws 36 and 41

242 Cat

Clean all parts and check the following:

• That the muffler and muffler mountings are not cracked or otherwise damaged.

• That the gaskets are OK.

Assemble the muffler and fit to the cylinder. Tightening torque, see page

20.

WARNING! The coating on and in the cata-

lytic converter element (A) is hazardous to your health if touched. Wear protective gloves when working on a catalytic converter

Other saws

Tighten all bolts using the tightening torque set out in the "Service data".

See "Service data" regarding tightening torques.

1. Secure the muffler on the cylinder using the two

2. Assemble the muffler components using the four

3. Secure the muffler to the crankcase using the two

Only specially treated bolts may be used on the catalytic converter (high temperature). See spare parts catalogue.

bolts (D). bolts (E). bolts (F) and Loctite.

50 – English

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SAFETY EQUIPMENT

Stop switch

Dismantling

Remove the earth screw (A) and cable (B).

Press the switch's securing tabs (C) towards each other and push out the switch.

Cleaning and Inspection

Clean the switch and check its resistance as follows:

Connect an ohm meter as shown in the fig. The resistance should be: In the stop position less than 0.1 ohm. In the run position more than 1000 ohm.

Assembly

Press the switch into the socket on the tank unit.

Fit the earth screw (A) and cable (B). Note! On some models the earth cable should

be connected to the earth screw.

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SAFETY EQUIPMENT

Throttle lock

Dismantling

WARNING!

Saws 40, 45.

See continuation on next page.

Other saws.

Remove the tank unit from the engine assembly. See page 103.

The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

Dismantle the throttle lock pin (A) using a punch.

Saw 394

Turn the throttle lock as shown in the figure, and lift it out with the spring from the cut-out in the handle.

Saws 61, 268, 268K, 272XP , 272K, 272S, 281XP, 288XP and

394.

Saws 61, 268, 272XP , 272K, 272S, 281XP and 288XP.

Slide the throttle lock and remove it forwards as shown in the figure.

Saw 3120. See continuation on next page.

Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP, 257 and 262XP.

Carefully prise up the lock from the slot and remove.

52 – English

Continues on next page.

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SAFETY EQUIPMENT

Saws 61, 268, 268K, 272XP , 272K, 272S, 281XP, 288XP and 394.

Dismantle the throttle pin (B) by using a punch.

Dismantle the throttle. On saw 394, also remove the throttle cable.

Saws 36, 41, 42, 55, 242XP , 246, 51, 254XP , 257 and 262XP.

Remove the rubber element (A). Slide out the throttle pin (B) and lift out the throttle arm and spring.

Saw 3120

Saws 40 and 45

Remove the three screws in the side of the handle as well as the screw holding the spring under the handle.

Lift out the throttle lock and the throttle.

Remove the three pins with a punch.

Press the throttle lock down and move it and the trigger forwards until the back edge of the lock appears.

Lift out the trigger lock.

Lift out the throttle with cable from the front.

Remove the springs where appropriate.

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English – 53

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SAFETY EQUIPMENT

Cleaning and inspection

Clean all parts.

Check that the lock's activation mechanism is not worn. For examples of the activation mechanism, see the figure.

Check that the springs, where fitted, are OK and have the correct tension.

On those saws fitted with a throttle cable, check that the cable and lever are OK and run freely.

54 – English

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SAFETY EQUIPMENT

Assembly

Saws 36, 40, 41, 45, 42, 242XP, 246, 51, 55, 254XP , 257 and 262XP.

Saws 36, 41, 42, 242XP , 246, 51, 55, 254XP , 257, 262XP and 394.

On saw 394, fit the cable to the trigger. Insert them into the handle from the front.

Other saws.

Fit springs in appropriate cases.

Saws 61, 268, 268K, 272XP , 272K, 272S, 281XP and 288XP. See next page.

Fit the cable to the trigger and install the throttle lock and trigger.

WARNING! The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

Saws 40, 45.

Fit the trigger with the cable from the front.

Saw 3120.

Fit the pin (B) and spring (when used).

All saws except 40 and 45 continue on the next page.

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Fit the side of the handle using three screws on the side and one underneath, which holds the spring.

Fit the spring and slide the throttle lock forwards from above so that its rear edge can be slid in under the edge of the handle.

English – 55

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SAFETY EQUIPMENT

Saws 36, 41, 42, 242XP , 246, 51, 55, 254XP , 257, 262XP and 394.

Fit the throttle lock and spring. On saw 394, twist as shown in the figure when fitting.

Saws 61, 268, 268K, 272XP , 272K, 272S, 281XP and 288XP.

Fit the throttle arm and spring. Fit the pin and the two rubber dampers.

Saw 3120.

Fit the three pins that hold the cable bracket, throttle lock and trigger.

Fit the throttle lock from the front.

Fit the throttle lock pin.

Fit the tank unit. See page 105.

56 – English

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STARTER

Dismantling

Dismantle the starter See the operating instructions.

Pull out the cord 20-30 cm andinsert it into the cut-out in the starter pulley rim. Some saws have several long cut-outs.

Rotate the starter pulley anticlockwise until the spring-tension on the starter pulley ceases.

Dismantle the starter pulley's centre bolt and washer.

WARNING! If the spring tension is released

Lift out the starter pulley carefully.

If the starter has a cord guide (A), remove this

If the cord is to be replaced, cut it off and pull out the bits from the handle and starter pulley using a pair of long nosed pliers.

when lifting the starter pulley, the spring can fly out and cause personal injury! Wear protective glasses!

WARNING!

If the spring is to be replaced, remove the old spring from the starter pulley. Some saws have a protective plate over the spring.

Ensure that the spring does not fly out and cause personal injury! Wear protective glasses!

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STARTER

Cleaning and Inspection

WARNING!

Ensure that the spring does not fly out and cause personal injury!

Changing the ferrule

Remove the parts of the old ferrule.

Clean all parts and check the following: The starter cord. The dogs in the starter pulley. That the pawls on the flywheel are OK, and

spring back towards the centre and move freely.

Fit the new ferrule in the starter housing.

Use a wrench, spacer (A) and ball (B). Splay out the ferrule on the inside as shown in the figure.

B A

58 – English

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STARTER

Assembly

WARNING!

If a new spring is to be fitted, position in its security/holder so that the eye is over the stud in the starter cover.

Slide in the spring and remove the security/ holder.

Ensure that the spring does not fly out and cause personal injury!

If a new cord is to be fitted, put the free end in the hole on the starter pulley . Grip the end using long nosed pliers and pull the cord through.

36 and 41.

Screw the cord to the starter pulley .

61, 268, 272, 281 and 288.

Secure the cord on the starter pulley.

42, 242, 246, 51, 55, 254, 257,262, 394 and 3120.

Knot the cord on the starter pulley .

Continues on next page.

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STARTER

Grease the return spring and starter pulley bearing.

If the starter unit has a cover plate (B) over the spring, fit the plate.

Fit the starter pulley. Rotate back and forth until the starter pulley catches in the spring.

Fit the starter pulley washer and bolt and tighten the bolt to 4 Nm.

If the starter has a cord guide (A), fit this.

Pull out the cord through the hole in the cover and fit the handle, secure with a double knot.

Pull out the cord 20-30 cm and insert it into the cut-out on the starter pulley rim. Some saws have several long cut-outs.

Rotate the starter pulley clockwise until the cord is correctly tensioned.

Check the cord tension

A. Pull out the cord completely and hold the

pulley with your thumb.

B. In this position it should be possible to turn

the starter pulley a further 1/2 - 3/4 turn.

Fit the starter on the crankcase. Tighten the bolts to 4 Nm.

60 – English

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ELECTRICAL SYSTEM

Ignition system

In the event of a fault in the ignition system the ignition module should be checked before dismantling the ignition system.

Check the ignition module as follows:

• Connect test spark plug 502 71 13-01 to the HT lead and clamp the test spark plug to the cylinder.

• Turn the engine over using the starter.

• If the test spark plug sparks the ignition module is OK.

Dismantling

Remove the cylinder cover and the starter unit.

Remove the spark plug and fit the piston stop.

Loosen the cable that runs to the stop switch from the ignition module.

Saws 36 and 41.

Release the cables from the guide rail and remove the guide rail.

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• Loosen the flywheel nut and unscrew it 1 turn

• Tap the nut quickly with a hammer so that the flywheel comes loose

• Remove the nut and flywheel.

Other saws, see next page.

English – 61

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ELECTRICAL SYSTEM

All saws except 36 and 41.

Unscrew the two pawls and springs located on the flywheel.

Fit puller 502 51 49-02 and loosen the flywheel.

Remove the puller, nut and flywheel.

Loosen the flywheel nut and undo until it aligns with the end of the shaft.

Continuation all saws

Remove the ignition coil.

The generator can be unscrewed if the saw is fitted with a handle heating system. Remove all parts so that the cable can be released. See applicable sections.

62 – English

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ELECTRICAL SYSTEM

Cleaning and Inspection

Clean all parts, especially the flywheel and shaft taper. Check that the flywheel is not cracked or damaged in any other way.

Assembly

Fit the generator if the saw is fitted with handle heating. Tighten the bolts to 4 Nm and lock using Loctite. Fit the cable to the actual contact on the saw. Adjust the length of the cable by knotting it.

Place the flywheel on the crankshaft. Rotate gently until the flywheel's key mates in the keyway on the shaft

• Replace the flywheel washer and nut. Tightening torque, see "Service data".

• Remove the piston stop.

• Fit the ignition module without tightening the screws.

• Turn the flywheel so that its magnet is beside the ignition module.

Continue assembly on next page.

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ELECTRICAL SYSTEM

• Insert feeler gauge 502 51 34-02 (0.3 mm) between the ignition module and the flywheel's magnet.

• Push the ignition module towards the flywheel and tighten the bolts to 4 Nm.

Fit the guide rail, insert the cables and fit the cable to the ignition module.

Saws 42, 242, 246, 281 and 288.

Fit the ignition coil, which is located next to the carburettor and connect the cables. Fit the starter and cylinder cover.

Fitting the spark plug cover

Make a hole in the HT cable using pliers 502 50 06-01.

Other saws.

Fit the starter and cylinder cover.

Push the HT cable through the spark plug cover and fit the contact spring using the pliers.

Slide the spark plug cover over the contact spring.

Stop switch

The stop switch is described in the section "Safety equipment". See page 51.

64 – English

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ELECTRICAL SYSTEM

Handle heating

Description

Some saws are equipped with an electric handle heating. This consists of the following parts:

• Generator.

• Power switch.

• Heater loop in the tank unit.

• Handle loop with heater loop. (One or two loops).

The above components are connected in series, which means that if there is a fault in one, all components stop working. The wiring diagram is shown in the figure to the right. The order of components can vary from saw to saw.

Trouble shooting

Trouble shooting can take place with most components connected to the saw. An ohm meter is required for trouble shooting.

Before trouble shooting individual components remove the power switch and disconnect one of the switch's cables. Remove other components as necessary. E.g. the cylinder cover. See the operating instructions.

Measurement points: A1 and A2 Earth. E.g. the cylinder A1 - B Measurement of the generator B - C Measurement of the handle loop C - D Measurement of the heater loops

in the rear handle

D - A2 Measurement of the power switch

Trouble shooting individual components, see next page.

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ELECTRICAL SYSTEM

Checking the generator

Connect the ohm meter to the cylinder (point A1) and point B. The ohm meter should read 0.9-1.3 ohm. Replace a generator that has higher or lower values.

Check the handle loop

Connect the ohm meter to points B and C. The ohm meter should read 3-4 ohm. Replace the handle loop that has a higher value.

Checking the heat loops in the rear handles

Connect the ohm meter to points C and D. The ohm meter should read 0.7-2.5 ohm. Replace a heat loops that has higher values.

Checking the power switch

Connect the ohm meter across the switch. The ohm meter should read more than 1000 ohm with the switch in position "0". The ohm meter should read, at the highest,

0.1 ohm with the switch in position "1".

66 – English

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CENTRIFUGAL CLUTCH

Dismantling

Remove the bar and chain. See the operating instructions. On 268K and 272K, remove the cutting attachment. See the operating instructions. On 272S, remove the grinder attachment. See the operating instructions.

Remove the spark plug and insert the piston stop.

Use a spanner and remove the clutch. On saws 36 and 41 use the service tool no. 530 03 11-12. Note! Left-hand thread.

Saws with three coil springs.

Remove the springs using a screwdriver. Then remove the clutch shoes.

Saws with one long spring.

Remove the spring by first lifting a shoe using a suitable spacer (A). Then remove the clutch shoes.

Saws with three C-springs.

Prise out the spring heels using a screwdriver. Remove the springs from the other side using circlip pliers. Then remove the clutch shoes.

Remove the clutch drum and needle bearing.

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CENTRIFUGAL CLUTCH

Cleaning and Inspection

Clean all parts and inspect the following:

Clutch shoes without chamfers.

That measurement A is not below 1 mm.

Clutch shoes with chamfers.

That measurement B is not under 1 mm.

68 – English

Check that there is no play between the clutch shoe and clutch hub

Check for wear on the chain sprocket. Check the condition of the needle bearing

and the bearing surface on the crankshaft. That the clutch drum friction surface and

bearing surface are undamaged.

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CENTRIFUGAL CLUTCH

Assembly

Grease the needle bearing (C) and fit onto the crankshaft. Then fit the clutch drum.

NOTE! The bearing can also be greased later through the hole on the crankshaft.

T o prevent imbalance all clutch shoes should be replaced at the same time.

Saws with three coil springs.

Locate the clutch shoes on the hub and fit the springs with the help of pliers.

Saws with one long spring.

Locate the clutch shoes on the hub. Lift a shoe using a suitable spacer (A) and fit the spring.

Saws with three C-springs.

NOTE! The clutch springs should not be opened out more than necessary. Risk of deformation.

Locate the clutch shoes on the hub and fit the springs with the help of circlip pliers.

Using a spanner secure the clutch centre. On saws 36 and 41 use service tool no. 530 03 11-12. Note! Left-hand thread.

Remove the piston stop and fit the spark plug.

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Fit the chain and bar. See the operating instructions. On 268K and 272K, fit the cutting attachment. See the operating instructions.

English – 69

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LUBRICATION SYSTEM

Dismantling

Dismantle the following parts: • Starter. See the operating instructions

• Centrifugal clutch. See page 67.

Saws 36, 40, 41, 45, 51 and 55. See page 72

Saws 61, 268, 272XP. See next page.

Saws 281XP and 288 XP. See next page.

Saw 394. See page 72.

Saw 3120. See page 72

Remove the pump drive and washer.

Undo the three bolts (A) and remove the oil pump. Some pumps have to be removed by using extractor screws. M5 screws should be inserted into the 2 threaded holes in the pump body and tightened equally to lift the pump and thrust washer. Other pumps have a cut-out (C) for a screwdriver to prise off the pump. Both types are shown below.

Other saws.

Saws 42, 242XP, 246, 254XP, 262XP and 257.

Dismantle the oil pump as follows:

1. Unscrew screw (A) and remove locking clip (B).

2. Undo screw (C).

3. Lever out the pump piston (D) and plastic plug (E) using a screwdriver.

4. Remove the seal (F).

A B C

B A

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LUBRICATION SYSTEM

Saws 61, 268, 272XP.

Dismantle the oil pump as follows:

1. Remove the lock washer (A), washer, spring and adjuster screw (B).

2. Remove the locking lacquer and undo screw (C).

3. Knock the edge of the pump housing against a piece of wood so that the pump piston (D) slides out of the housing.

4. Remove the pinion (E) with washers and springs.

5. Remove the pin (F).

6. Remove the seal (G).

7. If necessary remove the O-ring (H).

E C D

F B G

A H

Saws 281XP and 288 XP.

Dismantle the oil pump as follows:

1. Undo the adjuster screw (A).

2. Remove the plug (B) with pump piston (C) and spring with washers.

3. Dismantle the O-ring (D). Replace if necessary.

4. If necessary, replace the seal (E).

5. If necessary, replace the O-ring (F).

F A

D E

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LUBRICATION SYSTEM

Saw 394.

Dismantle the oil pump as follows:

1. Dismantle the screw (A) so that the spring and latch pin (B) can be removed.

2. Lever out the pump piston (C) with the plastic plug (D) using a screwdriver.

3. Remove the seal (E).

Saw 3120.

Dismantle the oil pump as follows:

Undo the three bolts that hold the oil pump and lift up the pump by the cut-out for the adjuster screw. Lift off the pump and loosen the wire for manual oil supply.

1. Undo the screws (A) and remove the parts as shown in the figure below.

2. Undo screw (B). NOTE! Left-hand thread.

72 – English

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LUBRICATION SYSTEM

Saws 36, 40, 41, 45, 51 and 55.

Dismantle the chain guide plates as shown in respective diagrams below.

36/41 40/45 51/55

Saws 36, 40, 41 and 45.

Undo the two bolts and lift off the pump and the upper seal.

Saws 51 and 55.

Lift off the pump and the upper seal.

Take the pump apart as shown in the exploded view on the next page.

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LUBRICATION SYSTEM

36/41

D E F G

CB A

D E F G

E F

B C

40/45

A. Lower seal. B. Pump cylinder. C. Upper seal. D. Chain guide plate. E. Pump housing. F. Pump piston. G. Worm gear.

50/51

CB A

74 – English

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LUBRICATION SYSTEM

Dismantling the oil pump's worm gear

On some saws the worm gear for the oil pump is pressed on the crankshaft.

Remove the worm gear by using the service tool for the saw in question. See "Tools".

First screw the tool onto the entire worm gear Turn the screw until the worm gear is removed.

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LUBRICATION SYSTEM

Cleaning and Inspection

Clean all parts and check the following when appropriate to the saw in question.

That the taper on the adjuster screw shows no signs of wear.

That the pump piston's eccentric face does not show signs of wear.

That the pump piston's pinion gear is undamaged.

That the worm gear on the oil pump drive is undamaged.

That all seals are undamaged.

The oil pipe is not blocked and the filter screen is clean.

76 – English

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LUBRICATION SYSTEM

Assembling the worm gear

On those saws where the oil pump worm gear is pressed on the crankshaft.

Assembling the oil pump

Saws 42, 242XP, 246, 254XP, 262XP and 257.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts.

2. Insert the pump piston (D) with washers and spring.

3. Press in the pump piston a little more and screw in the adjuster screw (C).

4. Insert the plastic plug (E).

5. Refit screw (A) and locking clip (B).

6. Fit the seal (F).

Screw the worm gear into the dismantling tool and press the worm gear onto the crankshaft until it bottoms against the collar.

B A

Saws 61, 268, 272XP.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts.

2. Fit the seal (G) if necessary.

3. Press in pin (F).

4. Locate the pinion (E) with washers and spring.

5. Insert the pump piston (D) through the pinion, spring and washers in the pump housing.

6. Fit screw (C). The screw should be locked using Loctite or locking lacquer.

7. Fit the adjuster screw (I) with washers, spring and locking clip (A).

8. Fit the O-ring (H).

F B

See continuation, page 80.

E C D

A H

See continuation, page 80.

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LUBRICATION SYSTEM

Saws 281XP and 288 XP.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts

2. Fit the seal (E) if necessary.

3. Fit the plug (B) and spring with washers on the pump piston (C) and fit the unit in the pump housing.

4. Fit the adjuster screw (A) in the pump housing, and through the hole in plug (B).

5. Fit the O-rings (D) and (F).

Saw 394.

F A

D E

See continuation, page 80.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts.

2. Fit the pump piston (C) with washers and spring in the pump housing.

3. Fit the latch pin (B), press in the pump piston (C) a little more and fit the adjuster screw (A).

4. Fit the seal (E).

5. Fit the plug (D).

See continuation, page 80.

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LUBRICATION SYSTEM

Saw 3120.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts

2. Fit the seal (C).

3. Fit the pump piston (D) with spring. Press in the piston and hold it in position with a screwdriver from the pump housing's inside in slot (E).

4. Fit screw (B) so that it is positioned approx. one turn from the bottom. NOTE! Left-hand thread

5. Fit lever arm (F).

6. Fit units (B-F-G) with spring (H) and screw in position using screws (A) and latch (J).

7. Remove the screwdriver.

8. Fit a new O-rings (K) and (L).

FDE

Fit the wire for manual oil supply.

See continuation on next page.

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LUBRICATION SYSTEM

Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and 3120.

Saws 61, 268, 272, 281 and 288

Use the tapered sleeve which is placed on the shaft when fitting the oil pump. Otherwise the seals will be damaged.

1. Lubricate the pinion gear with grease.

2. Fit the oil pump on the saw by tightening the three bolts.

3. If the tapered sleeve has been used, remove it.

4. Fit the centrifugal clutch.

See page 69.

5. Fit the bar and chain.

Adjust the oil pump for the correct oil flow.

See the operating instructions.

80 – English

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LUBRICATION SYSTEM

Saws 36, 40, 41, 45, 51 and 55.

Fit the oil pump as follows:

1. Apply SAE 30 oil to all moving parts.

2. Fit the worm gear (G) on the

crankshaft, if necessary

3. Fit the pump piston (F) in the pump

cylinder (B).

4. Fill the pump recess with grease.

5. Fit the unit in the pump housing (E).

Ensure the pump cylinder's cut-out aligns in the pump housing.

6. Fit the lower seal (A) on the crankcase.

D E F G

CB A

36/41

A. Lower seal. B. Pump cylinder. C. Upper seal. D. Chain guide plate. E. Pump housing. F. Pump piston. G. Worm gear

E F

B C

40/45

D E F G

CB A

50/51

Saws 36, 40, 41 and 45, see continuation on the next page.

Saws 51 and 55, see continuation on the next page.

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LUBRICATION SYSTEM

Saws 36, 40, 41 and 45.

Fit the oil pump in the crankcase, tighten the two bolts and fit the upper seal.

Fit the chain guide plates according to respective diagrams below.

Saws 51 and 55.

Fit the oil pump in the crankcase and fit the upper seal.

82 – English

36/41 40/45 51/55

Fit the bar and chain.

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CARBURETTOR

Description

The diagrams in this description do not correspond with the carburettor fitted on the chain saws. They serve only to show the principles of design and operation.

Design

The carburettor consists of three sub-systems:

• Metering unit, A.

• Mixing venturi, B.

• Pump unit, C.

The metering unit (A) contains the jets and fuel control functions. It is here the correct amount of fuel for the given engine speed and power is metered.

WARNING! The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

The mixing venturi (B) houses the choke, throttle valve and diffuser jets. Here air is mixed with the fuel to give a fuel/air mixture that can be ignited by the ignition spark.

In the pump unit (C), fuel is pumped from the fuel tank to the metering unit. One side of the pump diaphragm is connected to the crankcase and pulses in time with the pressure changes in the crankcase. The other side of the diaphragm pumps the fuel.

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CARBURETTOR

Operation

The carburettor operates differently in the following modes:

• Cold start

• Idling

• Part throttle

• Full throttle

In the cold start mode the choke valve (D) is fully closed. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets (E, F and G). The throttle valve (H) is partly open.

DEFG

In the idling mode (H) the throttle valve is closed. Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied through the diffuser jet (G).

In the part throttle mode the throttle valve (H) is partially open. Fuel is supplied through the diffuser jets (F and G).

HFG

In the full throttle mode both valves are open and fuel is supplied through all three diffuser jets (E, F and G).

84 – English

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EFG

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CARBURETTOR

Dismantling

WARNING!

Dismantle all parts necessary and remove the carburettor from the saw. On some models the cylinder needs to be loosened and lifted to be able to remove the carburettor.

The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

See the carburettor in question on the next four pages and the instructions below.

Plugs

When cleaning the carburettor the plugs must be removed. Remove as follows:

1. Drill a hole in the plug.

2. Insert a screwdriver or punch in the hole and prise up the plug.

”Semi fixed jet”/”fixed jet”

Some carburettors have an extra jet (semi fixed jet). The jet is of brass and is located in the metering unit and is used to give a fuel supplement. On average 10% of the fuel passes through the jet. Below or next to the jet is a screen which needs to be cleaned.

Dismantle the jet and/or screen in one of the following ways:

1. Knock the unit into the venturi using a punch and take the unit apart. (some Tillotson models).

2. Dismantle the lock washer over the jet and lift off the jet and screen.

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CARBURETTOR

Tillotson HS 228 B

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plugs (J).

See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

E F G

J C

B A

Tillotson HS 255 B

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plugs (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

B A

E F G

H K

8. Remove the speed governor (I). (Only 272K, 268K and 272S).

Remove the ”semi fixed jet” (K). See page 85.

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CARBURETTOR

Tillotson HS 260 A

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plugs (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

E F G

H K

B A

Remove the ”semi fixed jet” (K). See page 85.

Walbro HDA and HD

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plug (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

A B

H C

G F E

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CARBURETTOR

Walbro WJ

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plug (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

E F G

B A

Remove the ”semi fixed jet” (K). See page 85.

Walbro WG

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the low speed jet screws.

6. Remove the plugs (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

Remove the ”semi fixed jet” (K). See page 85.

A B

H C

K J

D G F E

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CARBURETTOR

Walbro WT

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. Remove the plug (J). See page 85.

7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

Remove the ”semi fixed jet” with diffuser jet (K). See page 85.

C J

BH K A

F G

ZAMA C1Q-EL1

1. Remove the cover (A) over the metering unit and carefully remove the control diaphragm (B) with the gasket.

2. Undo the screw (H) and take out the needle valve (C) with lever arm, shaft and spring.

3. Remove the cover (E) over the pump unit and carefully remove the gasket (F) and the pump diaphragm (G).

4. Using a needle or the like carefully remove the fuel screen (D).

5. Unscrew the high and low speed jet screws.

6. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs.

C K

D G F E

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CARBURETTOR

Cleaning and Inspection

WARNING!

Clean all components in petrol. Wear gloves or skin protection cream.

The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

Use compressed air to dry the petrol on the components. Direct the air through all channels in the carburettor housing and ensure that they are not blocked.

Refer to the carburettor diagram in question on the previous pages and check the following:

1. That the gasket and pump and control diaphragms are undamaged.

2. That there is no play on the throttle and choke valve shafts.

WARNING! Never direct the compressed air jet towards the body. Air can be forced into the blood stream and can cause fatality.

3. That the needle valve and its lever are not worn.

4. That the fuel screen is undamaged

5. That the tips of the high and low speed jet screws are not damaged.

6. On Tillotson HS 255 B, that the speed governor (I) is clean.

7. That the air intake manifold is not cracked.

90 – English

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CARBURETTOR

Assembly

Refer to the carburettor in question on the next eight pages. A pressure test, see page 100, should be carried out after assembling and before the carburettor is refitted to the saw.

Plugs

When cleaning the carburettor the plugs must be removed. Reassemble as follows:

1. Place the plug in the hole with the convex side facing upwards.

2. Expand the plug by using a punch on the top side.

WARNING!

”Semi fixed jet”/”fixed jet”

Reassemble the jet and/or screen in one of the following ways:

The fuel used in the chain saw poses the following hazards:

1. The fluid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

1. Put together the unit and fit it in the carburettor by means of a punch (Some Tillotson models).

2. Fit the jet with screen and lock washer.

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CARBURETTOR

Tillotson HS 228 B

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

4. Fit the fuel screen (D) by using the handle of a small screwdriver.

5. Fit the pump diaphragm (G), gasket (F) and cover (E) on the pump unit.

E F G

J C

B A

6. Fit the needle valve (C) with lever arm, shaft and spring and tighten screw (H).

7. Check, using or a ruler or the like, that the lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

8. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit.

9. Carry out a pressure test. See page 100

92 – English

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CARBURETTOR

Tillotson HS 255 B

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the ”semi fixed jet” (K). See page 91.

4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

5. Fit the fuel screen (D) by using the handle of a small screwdriver.

6. Fit the pump diaphragm (G), gasket (F) and cover (E) on the pump unit.

B A

E F G

H K

7. Fit the needle valve (C) with lever arm, shaft and spring and tighten screw (H).

8. Check, using or a ruler or the like, that the lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

9. Fit the speed governor (I). Lock with Loctite or locking lacquer. (Only applies to 272K, 268K and 272S).

10. Fit the control diaphragm (B) with gasket

and cover (A) on the metering unit.

11. Carry out a pressure test.

See page 100.

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CARBURETTOR

Tillotson HS 260 A

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the ”semi fixed jet” (K). See page 91.

4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

5. Fit the fuel screen (D) by using the handle of a small screwdriver.

6. Fit the pump diaphragm (G), gasket (F) and cover (E) on the pump unit.

E F G

H K

B A

7. Fit the needle valve (C) with lever arm, shaft and spring and tighten screw (H).

8. Check, using or a ruler or the like, that the lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

9. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit.

10. Carry out a pressure test. See page 100.

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Page 95

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CARBURETTOR

Walbro HDA och HD

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts,

lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the high and low jet screws and springs.

NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

4. Fit the fuel screen (D) by using the handle

of a small screwdriver.

A B

H C

G F

5. Fit the pump diaphragm (G), gasket

(F) and cover (E) on the pump unit.

6. Fit the needle valve (C) with lever arm,

shaft and spring and tighten screw (H).

7. Check, using or a ruler or the like, that the

lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

8. Fit the control diaphragm (B) with gasket

and cover (A) on the metering unit.

9. Carry out a pressure test. See page 100

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English – 95

Page 96

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

CARBURETTOR

Walbro WJ

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the ”semi fixed jet” (K). See page 91.

4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

5. Fit the fuel screen (D) by using the handle of a small screwdriver.

E F G

6. Fit the pump diaphragm (G), gasket (F) and cover (E) on the pump unit.

7. Fit the needle valve (C) with lever arm, shaft and spring and tighten screw (H).

8. Check, using or a ruler or the like, that the lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

9. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit.

10. Carry out a pressure test. See page 100.

96 – English

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Page 97

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

CARBURETTOR

Walbro WG

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts,

lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the ”fixed jet” (K). See page 91.

4. Fit the high and low jet screws and springs.

NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

5. Fit the fuel screen (D) by using the handle

of a small screwdriver.

6. Fit the pump diaphragm (G), gasket

(F) and cover (E) on the pump unit.

7. Fit the needle valve (C) with lever arm, shaft

and spring and tighten screw (H).

H C

K J

D G F E

8. Check, using or a ruler or the like, that the

lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

9. Fit the control diaphragm (B) with gasket

and cover (A) on the metering unit.

10.

Carry out a pressure test. See page 100.

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English – 97

Page 98

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

CARBURETTOR

Walbro WT

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the plugs (J). See page 91.

3. Fit the ”semi fixed jet” (K). See page 91.

C J

F G

4. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

5. Fit the fuel screen (D) by using the handle of a small screwdriver.

6. Fit the pump diaphragm (G), gasket (F) and cover (E) on the pump unit.

7. Fit the needle valve (C) with lever arm, shaft and spring and tighten screw (H).

8. Check, using or a ruler or the like, that the lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

9. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit.

Carry out a pressure test. See page 100.

10.

BH K A

98 – English

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Page 99

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

CARBURETTOR

ZAMA C1Q-EL1

Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems.

1. If the throttle and choke valves, shafts,

lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil.

2. Fit the high and low jet screws and springs.

NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips.

C K

3. Fit the fuel screen (D) by using the handle

of a small screwdriver.

4. Fit the pump diaphragm (G), gasket

(F) and cover (E) on the pump unit.

5. Fit the needle valve (C) with lever arm,

shaft and spring and tighten screw (H).

6. Check, using or a ruler or the like, that the

lever arm is level with the chamber floor. See the figure to the lower right. The lever arm can be bent if necessary to achieve the correct settings.

7. Fit the control diaphragm (B) with gasket

and cover (A) on the metering unit.

Carry out a pressure test. See page 100.

D G F E

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English – 99

Page 100

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

CARBURETTOR

Pressure testing

WARNING! The fuel used in the chain saw poses the following hazards:

1. The liquid and its vapours are poisonous.

2. Can cause skin irritation.

3. Is highly inflammable.

Pressure testing should be carried out with the carburettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but a test can also be made for trouble shooting before dismantling.

Make the test as follows:

1. Set the high and low speed jet screws one turn open from the bottom.

2. Connect pressure tester 502 50 38-01 to the carburettor’s fuel intake.

3. Lower the carburettor into a beaker of water.

4. Pump up the pressure to 50 kPa (0.5 bar) and clamp the pump tube with the spring clip.

5. There should be no leakage. If a leakage occurs refer to the table below.

Leakage on Fault with Diffuser jets Needle valve Leakage on the Pump diaphragm

pulse tube Ventilation hole Control diaphragm

above the metering unit

Refitting onto chain saw

Fit the carburettor to the chain saw and refit any other parts removed. For tightening torques, see the ”Service data” for the saw in question.

100 – English

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Carburettor adjustment. See the operating instructions for the saw in question.