Workshop Manual
Chain Saws
Contents
General recommendations |
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2 |
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1. |
Safety equipment |
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2. |
Starter unit |
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3. |
Electrical system |
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4. |
Fuel system |
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5. |
Centrifugal clutch |
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6. |
Lubrication system |
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65 |
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7. |
Cylinder and piston |
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77 |
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8. |
Crankshaft and crankcase |
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93 |
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9. |
Tools |
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115 |
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10. |
Technical data |
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127 |
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This manual covers models:
2036/2040
2041/2045/2050
2054/2055
625/630/670
2077/2083
2095
1
General recommendations
Keep this in mind:
–Do not start the engine without the clutch and clutch drum fitted.
–Do not touch hot parts such as the silencer and clutch before they have cooled sufficiently to avoid burn injuries.
–Avoid getting petrol on bare skin or in the mouth.
–Wipe up spilled oil immediately from the floor to avoid slipping and subsequent injury.
–Do not use tools which are worn or fit badly, e.g. nuts and screws.
–Never start the engine indoors. Exhaust fumes are toxic!
+Always work on a tidy work bench.
+Always work methodically to be sure that all parts are correctly assembled and that screws and nuts are tightened.
+Use protective cream on your hands. It reduces the risk of infection and enables dirt to be more easily washed off. Prolonged contact with motor oil can be hazardous to health.
+Use special tools when so recommended in order to work correctly.
Fire hazard
Handle petrol with respect since it is highly inflammable.
Do not smoke and make sure that there are no naked flames or sparks in the vicinity.
Make sure that there is a functioning fire extinguisher in the vicinity.
Do not attempt to extinguish a petrol fire with water.
Toxic fumes
Read the instructions carefully when using cleaning liquids.
Make sure that there is adequate ventilation when handling petrol, trichloroethylene and other viscous liquids.
The engine exhaust fumes are toxic. Test run the engine only when there is good ventilation, preferably outdoors.
! WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
2
Special tools
Some work operations in this workshop manual require the use of special tools. In each section where this is appropriate the tool and order number are illustrated.
We recommend the use of special tools partly to avoid personal injury and partly to eliminate expensive damage to the components in question.
502 51 02-01
Sealing surfaces and gaskets
Make sure that all sealing surfaces are clean and free from the residue of old gaskets. Use a tool which will not damage the sealing surface when cleaning it. Scratches and irregularities are removed with a fine, float cut file.
Sealing rings
Always replace a sealing ring which has been dismantled. The sensitive sealing lip can easily be damaged and result in poor sealing capacity. The surface which the seal seals must also be completely undamaged. Lubricate the sealing lip with grease before it is fitted and make sure that it is not damaged, e.g. by shoulder and splines on a shaft. Use tape or conical sleeve as protection. It is important that the sealing ring is correctly turned for it to function as intended.
1
Safety equipment
1.
Contents
Dismantling |
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4 |
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Disassembly |
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4 |
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Fitting |
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Dismantling, mod. 2054/2055 |
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Fitting, mod. 2054/2055 |
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Dismantling, mod. 2077/2083 |
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Fitting, mod. 2077/2083 |
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Checking of automatic function |
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Checking of brake action |
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Chain catcher |
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Throttle lock |
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3
1 |
Safety equipment |
In addition to the chain brake the chain catcher and right-hand guard on the rear handle are also considered part of the chain saw’s safety equipment.
It is obviously important that the chain brake functions as intended, but it is also important that the chain catcher is undamaged and in position. In the event of a chain break this will catch up the chain so that the hand will not be injured.
!WARNING!
Protective goggles must be worn during all work on the chain brake to prevent personal injury if for some reason the brake spring should fly off.
Dismantling
Dismantle the chain brake from the chain saw.
Disassembly
Release the chain brake.
Press out the one half of the hand guard’s bearing.
Dismantling
Remove the guide bar's attachment nuts and lift off the clutch cover with the chain brake.
Clean from sawdust and dirt.
!WARNING!
The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work.
Disassembly
Release the chain brake.
Unscrew the screw to the hand guard’s bearing completely, and then screw in approx. 2 turns.
Drive out the bearing by tapping the screw with a hammer.
Press out the other half of the hand guard’s bearing.
Press out the other half of the bearing by means of suitable mandrel, e.g.
505 38 17-05.
Lift off the hand guard.
505 38 17-05
4
Safety equipment |
1 |
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Remove the screws and the cover over the brake spring.
Bend up the brake spring.
Press out the toggle-joint’s bearing pin and lift off the complete brake mechanism.
Press out the plate spring with a suitable mandrel.
Remove the screws and lift off the cover over the brake spring.
!WARNING!
The brake spring is tensioned and can slip out of its position.
Use a screwdriver and carefully bend up the spring.
Press out the toggle-joint’s bearing pin by means of a suitable mandrel.
Lift off the complete brake mechanism.
Press out the plate spring with a suitable mandrel, and replace if necessary.
Clench the spring eye with a pair of pliers so that it is easier to fit the new spring.
5
1 |
Safety equipment |
0,8 mm
6
The brake band must have a minimum thickness of 0.8 mm at the most worn point.
Remove the screw and replace the brake band.
Dismantle the lock-ring and the pin in order to replace the spring inside the hand guard.
Assembly
Grease the spring and fit it in the hand guard.
Check the wear on the brake band.
At the most worn point the band must have a thickness of at least 0.8 mm. Otherwise it should be replaced with a new band.
Remove the screw and fit a new brake band.
Check after fitting that the brake band does not touch the toggle-joint and obstruct its movement.
Inside the hand guard there is a spring which is accessible for replacement after the lock-ring and pin are dismantled.
Use a small screwdriver to remove the lock-ring.
Assembly
Grease the spring and push it in the hand guard as far as it goes.
Fit the pin and lock-washer.
NOTE!
The pin should not go through the eye on the spring.
Check that the spring is turned correctly.
Safety equipment |
1 |
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A
B
Fit the brake mechanism in the clutch cover.
Lubricate the bearing points with thin oil.
Press down the brake spring by means of a Phillips screwdriver.
Fit the cover.
Grease the bearing surfaces and fit the hand guard.
Check that the brake functions.
Dismantling
Mod. 2054/2055
Remove the screw, sleeve and washer for the hand guard’s bearing on the starter unit side, including the clutch cover, guide bar and chain.
Clean!
Place the brake mechanism in position on the clutch cover.
Press in the toggle-joint’s bearing pin (A) and place the tubular pin (B) in position.
Lubricate the bearing points with thin oil.
Press down the brake spring in the clutch cover by means of a Phillips screwdriver.
!WARNING!
Observe care to avoid injury if the screwdriver slips.
Fit the cover over the spring mechanism.
Grease the bearing points for the hand guard.
Press down the hand guard over the bearing and fit both bearing sleeves.
NOTE!
Check that the bearing sleeves are placed on the correct side.
Tension and release the chain brake a number of times to check that it functions.
Dismantling
Mod. 2054/2055
On these models the chain brake’s hand guard has an extra bearing point on the starter unit side.
Remove the screw, sleeve and washer for this bearing.
Remove the clutch cover, guide bar and chain.
Clean from sawdust and dirt.
7
1
8
Safety equipment
Dismantle the protective plate over the guide bar attachment and the chain brake.
Release the chain brake!
Remove the plate clamp over the brake spring and bend away the spring.
Remove the protective plate over the guide bar attachment.
Remove the screws and lift off the chain brake.
Release the chain brake!
!WARNING!
The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work.
Remove the screw and plate clamp over the brake spring.
Carefully bend away the spring by means of a screwdriver.
NOTE!
The spring has a certain tension even when the brake is released, and therefore it should be dismantled carefully.
Remove the lock-ring round the hand |
Remove the lock-ring round the hand |
guard’s bearing pin and lift off the brake |
guard’s bearing pin and lift off the brake |
mechanism. |
mechanism. |
Replace the plate insert in the hand guard |
If the pins on the plate insert in the hand |
if the pins are worn by first pressing out |
guard are worn the complete insert can |
the fitted pin. |
easily be replaced. |
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Press out the fitted pin with a suitable |
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mandrel and replace the insert. |
Safety equipment |
1 |
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Dismantle the brake mechanism and replace worn or damaged parts.
0,8 mm
Fit the brake spring and plate clamp over the spring.
Fit the chain brake on the crankcase.
Screw tight the cover plate over the guide bar attachment and fit the brake’s bearing on the starter unit side.
Dissassemble the brake mechanism and replace worn or damaged parts.
The brake band should have a minimum thickness of 0.8 mm at the most worn place.
Assembly
Mod. 2054/2055
Fit the brake in the reverse order to dismantling.
Begin with by fitting the hand guard.
Lubricate all moving parts with thin oil.
Fit the brake spring by means of a Phillips screwdriver.
!WARNING!
Observe care to avoid injury if the screwdriver slips.
Fit the plate clamp over the spring.
Fit the chain brake on the crankcase.
NOTE!
Make sure that the guide pin on the brake fits into the hole in the crankcase before the screws are tightened.
Fit the cover plate on the guide bar attachment.
Screw tight the screw for the brake’s bearing on the starter unit side.
Do not forget the washer between the crankcase and brake!
9
1 |
Safety equipment |
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Dismantling |
Dismantling |
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Mod. 2077/2083 |
Mod. 2077/2083 |
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Dismantle the chain brake’s bearing on |
Remove the screw, sleeve and washer |
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the starter unit side. |
for the chain brake’s bearing on the star- |
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Remove the clutch cover, guide bar and |
ter unit side. |
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chain. |
Remove the clutch cover, guide bar and |
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Clean! |
chain. |
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Remove the screws and lift off the chain |
Clean from sawdust and dirt. |
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brake. |
Remove the screws and lift off the chain |
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brake. |
Release the chain brake! |
Release the chain brake! |
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Lift up the toggle-joint carefully by means |
! WARNING! |
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of a screwdriver. |
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The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work.
Lift up the toggle-joint carefully by means of a screwdriver.
Hold your hand over.
NOTE!
The other end of the spring is controlled by a pin which goes into the centre.
For this reason do not try to lift up the spring there.
Dismantle the hand guard. |
Dismantle the hand guard. |
Remove the lock-ring by means of a small screwdriver.
Hold your thumb over so that the ring does not fly away.
Press the hand guard out of the bearing. |
Press out the hand guard from the bearing. |
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! WARNING!
Observe care so that the sprin loaded catch does not fly away.
10
Safety equipment |
1 |
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0,8 mm
Replace the hand guard’s bearing pin if it is worn.
Press out the sprung tubular pin and pull out the plate insert from the hand guard.
Clean and check all parts.
The thickness of the brake band should be at least 0.8 mm.
Assembly
Mod. 2077/2083
Fit the brake in the reverse order to dismantling.
Press down the hand guard in the correct position.
The hand guard’s bearing pin can now easily be replaced.
Press out the spring tensioned tubular pin and pull out the complete plate insert from the hand guard.
Replace the insert if the bearing pin is worn.
Clean all the parts of the chain brake and check them for wear or damage.
The brake band should have a minimum thickness of 0.8 mm at the most worn part.
Replace the brake band if it is worn more than this.
Assembly
Mod. 2077/2083
Fit the brake in the reverse order to dismantling.
Begin by fitting the hand guard.
Lubricate the bearing pin and catch with oil.
Place the catch in position with the extruding part downwards.
Press away the catch by means of a screwdriver and press down the hand guard in the correct position.
Fit the lock-ring on the bearing pin.
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1 |
Safety equipment |
A
B
L |
H |
12 |
Fit the brake band (A) and place the toggle-joint in position over its bearing pin (B).
Press together the brake spring far enough so that the guide pin in the back of the spring housing is released.
Press down the spring and check that the pin goes into the centre of the spring.
Press down the brake band in its rear attachment (A).
Place the toggle-joint in position over its bearing pin (B).
Make sure that it is correctly positioned.
Press the brake spring over the guide pin.
Push the guide sleeve in the spring and outside of the guide pin.
Press the spring together by means of a suitable Phillips screwdriver far enough so that the guide pin in the back edge of the spring housing is released.
Press down the spring and check that the pin goes into the centre of the spring.
Fit the chain brake on the engine.
Check that the guide pin on the chain brake goes into the corresponding hole in the crankcase.
Checking of the automatic function
NOTE!
The engine should be switched off during this check.
Hold the saw approx. H mm over a stable object.
Release the front handle and allow the saw to turn round the back handle by virtue of its own weight. When the guide bar point hits the object the brake should be activated.
H, cm/inch |
L, inch |
45/14 |
11 – 16 |
55/22 |
18 – 22 |
65/26 |
24 – 28 |
80/32 |
30 – 36 |
Safety equipment |
1 |
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Checking of the brake effect
Start the engine.
Hold the handle with both hands and rev up.
Release the chain brake by turning the left wrist towards the hand guard without releasing the grip round the front handle. The chain should stop immediately.
Chain catcher
Replace the chain catcher if it is deformed or cracked.
Throttle lock
Dismantling
Remove the screws.
Remove the handle half, throttle control and lock.
Checking of the brake effect
Place the saw on a stable surface and start the engine.
Hold the handle with both hands and rev up.
Release the chain brake by turning the left wrist towards the hand guard without releasing the grip round the front handle. The chain should stop immediately.
Chain catcher
The chain catcher has the purpose of catching the chain if it breaks.
It is therefore important that it is not deformed or cracked. Replace if this should be the case.
Throttle lock
Dismantling
Remove the screws which hold the handle halves together and where appropriate also the screw which holds the spring for the vibration damper.
Lift off the handle half and throttle control together with the lock.
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1 |
Safety equipment |
Fitting, mod. 2036/2040
Fit in the reverse order to dismantling.
Check that the throttle cable is correctly fitted.
Do not lubricate!
1
2
Fitting mod. 2041/2045/2050
Check that the throttle cable is correctly fitted.
Do not lubricate!
Fitting mod. 2054/2055
Check that the spring and throttle cable are correctly connected.
Fitting mod. 2036/2040
Replace any damaged parts and fit in the reverse order to dismantling.
Note the following:
●Make sure that the spring comes on the correct side of the barrier in the throttle control.
●Check that the throttle cable's ball lug sits in the recess (1).
●Check that the throttle cable is flush with the cam curve on the throttle control (2).
●Do not lubricate!
Fitting mod. 2041/2045/2050
Note the following:
●Fit the throttle cable from the correct side in the throttle control.
●Check that the throttle cable is correctly positioned so that it is not clenched when the handle half is fitted.
●Do not lubricate!
Fitting mod. 2045/2055
Note the following:
●The positioning of the spring in the throttle control.
●The connection of the throttle cable from underneath to the throttle control catch.
●Do not lubricate!
14
Safety equipment |
1 |
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Dismantling mod. 625/630/670
Press out the fitted pin and dismantle the cover.
Dismantle the spring and throttle control lock.
Fitting mod. 625/630/670
Fit the throttle control lock in the reverse order to dismantling.
Dismantling mod. 2095
Dismantle the handle half.
Dismantling mod. 625/630/670
Press out the fitted pin approx. 13-14 mm so that the throttle control lock comes loose.
Dismantle the covers by means of pressing a screwdriver into the back edge of the covers.
If the handle is electrically heated see chap. 3 ”Electrical system”.
Press out the sprung tubular pin which is located behind the cover far enough so that the spring and the throttle control lock can be lifted off.
Fitting mod. 625/630/670
Replace damaged or worn parts and fit in the reverse order to dismantling.
NOTE!
The sprung tubular pin should go through the spring eyelet.
Dismantling mod. 2095
Remove the screws and lift off the handle half.
15
1 |
Safety equipment |
2
1
Fitting mod. 2095
Replace damaged or worn parts and fit in the reverse order to dismantling.
Fitting mod. 2095
Replace damaged or worn parts.
Fit in the reverse order to dismantling.
Pay attention to the following:
●The spring’s straight shank should be fitted in the throttle control lock (1).
●Make sure the throttle wire housing is well pressed down in the recess (2).
●Check that the short-circuiting cable sits in the recess so that it is not clenched when the handle half is screwed tight.
16
2
Starter unit
2.
Contents
Dismantling |
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Replacement of return spring |
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19 |
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Replacement of starter cord |
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20 |
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Assembly |
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21 |
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Replacement of starter pawls |
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22 |
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2 |
Starter unit |
!WARNING!
When working on the starter unit wear protective glasses to avoid eye injuries in the event that the return spring flies out.
Dismantling
1.Dismantle the starter from the engine unit.
2. Release the spring tension.
3.Allow the pulley to slowly rotate backwards.
Dismantling
1.Remove all screws and lift off the starter.
2.Release the spring tension.
Pull out the starter cord approx. 30 cm. Brake the cord wheel with the thumb and place the cord in one of the recesses on the pulley.
3.Allow the pulley to slowly rotate backwards.
NOTE!
Brake the rotation with the thumb.
!WARNING!
Observe care so that the thumb is not injured by the reinforcement ribs on the pulley or the cord's attachment screw.
18
Starter unit |
2 |
4. Remove the screw and the washer.
5.Remove the pulley and spring cassette, and return spring.
!WARNING!
Wear protective glasses.
6. Dismantle the cover disc and return spring from the starter unit housing.
! WARNING!
Wear protective glasses.
Replacing return spring
Dismantle the pulley as described above.
A. Fit a new spring cassette.
4.Remove the screw and washer in the centre of the pulley.
5. Lift off the pulley carefully.
6A.Remove the screws which hold the spring cassette and lift off.
! WARNING!
Wear protective glasses. The return spring can fly out and cause injury.
6B.Remove the screws which hold the cover disc over the return spring.
Dismantle the spring by giving the starter housing a sharp tap against the work bench with the spring turned downwards.
!WARNING!
Wear protective glasses. The return spring can fly out and cause injury.
Replacing return spring
Dismantle the pulley as described above.
A.Place a new spring cassette in the starter housing and tighten the screw(s).
19
2
20
Starter unit
B.Press down a new spring in the starter housing.
! WARNING!
Wear protective glasses.
B. Return spring without cassette.
Leave the lock shackle round the spring in position.
1.Place the spring over its seat in the starter housing.
2.Press down the spring in the correct position by means of the thumbs and let the lock shackle slide over the spring.
3.Fit the cover plate off the spring.
!WARNING!
Wear protective glasses.
Replacing starter cord
1.Fit and lock the cord at the pulley as per one of the methods shown in the diagrams.
Tips!
The knot on the starter cord in the starter handle may be difficult to untie. It is easier if the knot is first knocked with a hammer against a hard surface.
2. Anchor the cord in the starter handle. |
2. Enter the cord through the socket in |
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the starter housing and anchor it in |
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the starter handle by means of a knot. |
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Fold down the free end and pull the |
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knot securely into the handle. |
Starter unit |
2 |
1 – 3 r
max
+ 1/2 r
Assembly
1.Wind the cord approx. 4 turns clockwise round the pulley.
2. Fit the pulley.
3. Increase the spring tension.
4.Check the spring tension.
With a fully withdrawn cord it should be possible to turn the pulley at least another half turn.
Assembly
1.Wind the cord approx. 4 turns clockwise round the pulley.
2.Lubricate the pulley’s bearing pin and the return spring with a few drops of motor oil or non-freezing lubricant and fit the pulley.
Check that the return spring grips the pulley. The spring may require to be bent out further from the bearing pin.
3.Put the washer in place and tighten the screw.
4.Increase the spring tension.
With a fully withdrawn cord it should be possible to turn the pulley at least another half turn.
Tension the spring more by:
●Pulling the cord approx. 30 cm and braking the pulley with the thumb.
●Lift up the cord in one of the recesses on the pulley.
●Wind the cord 1-3 turns clockwise round the hub of the pulley.
●Pull out the starter cord fully.
5.Check the spring tensions.
With a fully withdrawn cord it should be possible to turn the pulley at least another half turn.
Repeat the spring tensioning if necessary.
21
2 |
Starter unit |
5.Assemble the starter in the reverse order to dismantling.
503 21 22-01
Replacing starter pawls
See chapter 3 ”Electrical system”.
6.Assemble the starter.
Pull out the starter cord a little. Put the starter in position. Release the starter cord and check that the pawls grip the pulley.
Tighten the screws.
NOTE!
If the threads in the crankcase (made of plastic) are for any reason damaged an oversize screw (No. 503 21 22-01) is recommended.
Replacing starter pawls
See chapter 3 ”Electrical system”.
22
3
Electrical system
3.
Contents
Checking ignition spark |
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Replacing spark plug protection |
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26 |
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Dismantling |
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28 |
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Starter pawls |
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20 |
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Assembly |
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30 |
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Electrically heated handles |
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31 |
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Replacing the generator |
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33 |
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23
3 |
Electrical system |
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The chain saw is fitted with an electronic system |
NOTE! |
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consisting of flywheel, ignition coil, and trigger |
When testing the chain saw’s heating system the |
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unit. Certain saw models are fitted with a gene- |
guide bar, chain and clutch cover must be fitted |
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rator system to heat the handles and carburettor. |
before the engine is started! |
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The ignition system is electronic and completely |
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without moving parts. A |
defective component |
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cannot be repaired and must be replaced. |
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The ignition spark in an electronic ignition sys- |
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tem has a very short burn time and may therefore |
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be experienced as weak and sometimes difficult |
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to see during trouble shooting. |
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Checking ignition spark
Clean the electrodes and check the electrode gap.
If the electrodes are worn down more than 50% the plug should be replaced.
Check if there is a spark when starting.
Try with test plug No. 502 71 13-01 if there is no spark.
Checking ignition spark
Remove the plug and clean from soot by means of steel brush.
Check the electrode gap. It should be 0.5 mm – 0.7 mm (.020 – .028").
Adjust the gap to correct value with side electrode.
If the electrodes are worn down more than 50 % the plug should be replaced.
An overlarge gap implies stress on the ignition module and the risk of short circuiting.
Make sure that the stop contact is in start position.
Earth the plug to the cylinder and pull the start handle.
There should be a spark between the electrodes.
If there is no spark try with the test plug No. 502 71 13-01.
If there is a spark the fault lies in the plug.
Replace plug.
502 71 13-01
24
A
B
Electrical system |
3 |
Try with a new plug
If there is no spark disconnect the short circuiting contact.
Replace the contact if necessary.
Mod. 2077/2083
Check that the earth cable is undamaged and that it has metallic contact with the crankcase.
Check the connections of the ignition cable.
Try with a new plug.
If there is still no spark remove the short circuiting cable from either the ignition module or short circuiting contact.
If there is no spark the fault lies in the stop contact.
Replace the contact.
Mod. 2077/2083
Check that the earth cable between the crankcase and stop contact is undamaged and that it has metallic contact with the crankcase.
Use an ohm-meter and measure the resistance in the cable between the stop contact and connection at the crankcase.
The instrument should give a full reading if the cable is in good condition.
Still no spark?
Check the plug connection.
Pull off the rubber protection at the plug
(A) and ignition module (B) and check that the ignition cable is undamaged. Cut off a piece of the cable to ensure good contact.
Lubricate the cable ends with grease. |
Lubricate the cable ends with a little |
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grease to simplify fitting and prevent |
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moisture from penetrating into the connec- |
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tions. |
25
3
0.3 mm
26
Electrical system
Check other cables and connections.
Check the air gap.
502 51 34-05
Adjust the air gap.
Replacing spark plug protection
1.Take ignition cable through the spark plug protection.
2.Make a hole in the ignition cable for the contact spiral.
Still no spark?
Check the other cables and connections for poor contact (dirt, corrosion, cable break and damaged insulation).
Tips!
Use an Ohm-meter to check if there is a cable break, e.g. as a result of pinching.
Still no spark?
Check the air gap between the flywheel permanent magnet and ignition module. The gap should be 0.3 mm (.012").
Use air gap measure 502 51 34-05.
Adjust the air gap to correct size.
●Release screws.
●Place the feeler gauge and press the ignition module to the flywheel.
●Tighten the screws and check the air gap again.
If there is still no spark the ignition system should be replaced.
Replacing spark plug protection
1.Lubricate the ignition cable with a little grease and take it through the plug protection.
2.Cut off a piece of the ignition cable (approx. 5 mm, .20") and make a hole in the cable for the contact spiral by means of pliers No. 502 50 06-01.
502 50 06-01
Electrical system |
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3. Fit the contact spiral on the ignition cable.
Dismantling
Dismantle the plug, cylinder cover, starter unit, and air bar.
Dismantle the ignition module and release the other cable connections.
Fit a piston stop No. 504 91 06-05 alt. 502 50 33-01 in the spark plug hole.
504 91 06-05
Dismantle the starter pawls.
Mod. 2054/2055
On earlier versions of these models the starter pawls sit on a bridge which can be lifted off when the flywheel nut is dismantled.
3.Fit the contact spiral on the ignition cable and make sure that the wire is folded along the cable.
4.Pull the contact spiral into the spark plug protection.
NOTE!
It is important that the point of the contact spiral meets the middle of the ignition cable to prevent sparking.
Dismantling
Dismantle the plug, cylinder cover, starter unit, and air conductor.
Dismantle the ignition module by removing the two screws.
Release the other cable connections and lift off the ignition module.
Fit a piston stop No. 504 91 06-05 alt. 502 50 33-01 in the spark plug hole.
Make sure that the piston stop is screwed down to the bottom.
Dismantle the starter pawls by releasing the screws. Make sure that the small washer close to the flywheel is not mislaid.
Mod. 2054/2055
On earlier versions of these models the starter pawls sit on a bridge which can be lifted off when the flywheel nut is dismantled.
27
3
28
Electrical system
Remove the flywheel nut.
Pull off the flywheel.
502 51 49-01
Tips!
If the flywheel is tight give a few smart taps with a hammer on the extractor screw.
Mod. 2036/2040
Dismantle the flywheel by using a hammer.
502 51 94-01
Remove the flywheel nut by means of a suitable socket wrench.
Pull off the flywheel by means of withdrawing tool 502 51 49-01 which is screwed in the hole for the starter pawls.
NOTE!
Centre the withdrawing tool over the shaft centre. Select suitable screws and tighten the withdrawing tool.
Tips!
The flywheel may sit very tightly on the shaft.
To simplify dismantling give a few smart taps with a hammer on the extractor screw. Hold the chain saw in the air with the handle on the withdrawing tool.
Mod. 2036/2040
Thread the nut on the shaft to protect the threads.
Snap the springs loose and fold down the starter pawls to leave space for the hammer.
Grip the flywheel and lift up the engine unit.
Give a few smart blows with the hammer on the flywheel nut until the flywheel releases from the shaft.
Tips!
Use a pressure piece to protect the threads on the shaft and so that it is also easier to use the hammer.
Electrical system |
3 |
Mod. 2054/2055
Pull off the flywheel.
504 90 90-01
Starter pawls
Check the starter pawls for wear and damage.
Replace damaged parts.
Mod. 2036/2040
Press out the journals by means of a suitable mandrel.
Replace damaged parts.
Mod. 2054/2055
Pull off the flywheel by means of ball bearing puller No. 504 90 90-01.
NOTE!
The claws on the tool should be placed on and opposite the permanent magnet on the flywheel so that this is not damaged.
Is the flywheel stuck?
Lift up the engine unit by holding the tool and hit the tool screw a few times with a hammer.
Starter pawls
Check the starter pawls for wear and damage.
Replace damaged parts.
For starter pawls which are mounted on a separate bridge the entire unit must be replaced.
Mod. 2036/2040
Replace the starter pawls and springs in the following way if they are housed on a journal pressed in the flywheel.
Place the flywheel on support blocks and press out the journals by means of a suitable mandrel.
Replace damaged parts.
Make sure that the spring is not pinched when the journal is pressed into the flywheel.
Check that the starter pawls move easily.
29
3
0.3 mm
30
Electrical system
Assembly
Check that the keyway and key in the crankshaft are undamaged.
Check that the keyway and the cast key respectively in the flywheel are undamaged.
Fit the flywheel.
Fit the ignition module.
Adjust the air gap (0.3 mm, .012")
Fit the other cables.
Fit the other parts in the reverse order to dismantling.
When fitting the starter pawls check the following:
●Washer between flywheel and starter pawls.
●The spring is not clenched.
●The starter pawls move freely.
●Use Locktite on the screw.
Assembly
Check that the keyway and key in the crankshaft are undamaged.
Fit a new key and make sure that it fits correctly in the keyway.
Check that the keyway and cast key respectively in the flywheel are undamaged.
Fit the flywheel on the crankshaft and check that the key and keyway are correctly positioned before the flywheel nut is tightened.
Tighten the nut to a torque of 25–35 Nm
Fit the ignition module
Adjust the air gap to the correct size (0.3 mm, .012").
See also page 26.
Fit the other cables and make sure that they are correctly positioned in cable grooves etc. so that they cannot be damaged.
Fit the other parts in the reverse order to dismantling.
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