Husqvarna T540 XP Workshop Manual
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Husqvarna T540 XP Workshop Manual

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Workshop Manual
T540 XP
T540 XP II
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Summary of Contents for Husqvarna T540 XP

  • Page 1 Workshop Manual T540 XP T540 XP II English...

  • Page 3: Table Of Contents

    Safety equipment ..........16 Repair instructions ..........28 Carburettor ............38 Troubleshooting ........... 62 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English –...

  • Page 4: Index

    Index Index Numbering 7 Safety 7 Bar bolt 61 Special Instructions 8 Replacing the bar bolt 61 Structure 7 Symbols in the Workshop Manual 9 Symbols on the saw 9 Carburettor 39 Target group 7 Assembly 44 Tools 7 Cleaning and checking 43 Design 39 Dismantling 41 Piston and cylinder 54...
  • Page 5 Index Threads 62 Repairing damaged threads 62 Throttle lockout, throttle and spring 24 Assembling the throttle lockout, throttle and spring 25 Cleaning and checking 25 Dismantling the throttle lockout, throttle and spring 24 Troubleshooting 64 Troubleshooting techniques 65 Vibration damping system Assembly 53 Cleaning and checking 53 Dismantling 53...

  • Page 6: Introduction And Safety Regulations

    Introduction and safety regulations 2 Introduction and safety regulations List of contents General information ......................7 Safety ..........................7 Target group ........................7 Modifications........................7 Tools ..........................7 Structure .........................7 Numbering ........................7 General instructions ......................8 Special instructions ......................8 2.10 Symbols on the saw .......................9 2.11 Symbols in the Workshop Manual ..................9 –...
  • Page 7 Workshop Manual. In order to increase the basic understanding, some Usage is evident from the respective section. sections include a Description of the unit in question. Always use Husqvarna’s original: 2.7 Numbering • Spare parts Position references to components inside the •...
  • Page 8 Introduction and safety regulations 2.8 General instructions 2.9 Special instructions The workshop where the chain saw is to be The fuel used for the chain saw has the repaired must be equipped with safety devices in following hazardous properties: accordance with local regulations. •...
  • Page 9 Introduction and safety regulations 2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual The symbols below are embedded in the chain saw. This symbol warns of personal injury Choke control when the instructions are not followed. Use protective gloves. Refuelling Use protective goggles.

  • Page 10: Technical Data

    - rpm T540 XP: 28 - 38/11 - 15 25.8 / 10 200 9.53 / 0.375 1.3 / 0.050 T540 XP II 28 - 38/11 - 15 25.8 / 10 200 9.53 / 0.375 1.3 / 0.050 – English...
  • Page 11 Technical data Idle speed Engage speed Spark plug T540 XP: 3 000 4 400 NGK CMR 6H T540 XP II 3 000 4 400 NGK CMR 6H Volume fuel tank Capacity oil pump at Volume oil tank Automatic oil pump...

  • Page 12: Service Tools

    Service tools 4 Service tools – English...
  • Page 13 Service tools Pos. Description Used for Order No. Mounting kit for bearings Dismantling and assembling bearings 577 71 44-02 and sealing ring and sealing ring 1a Dismantling tool Dismantling bearings and sealing ring 576 66 64-01* 1b Assembling tool Assembling the sealing ring 576 95 56-02* 1c Dismantling tool Dismantling bearings and sealing ring 576 95 46-01* 1d Assembling tool Assembling bearings 576 95 45-01* 1e Dismantling tool Dismantling bearings and sealing ring 725 23 80-51* Assembling tool Assembling the sealing ring...

  • Page 14: Service Data

    Service data 5 Service data 6 ~ 8 Nm min 20 Nm 2,5 ~ 3,5 Nm 3 ~ 4 Nm 5,5 ~ 6,5 Nm 18 ~ 20 Nm 16 mm 8 ~ 10 Nm 6 ~ 8 Nm 8 ~ 10 Nm 8 ~ 10 Nm 2,5 ~ 3 Nm 8 ~ 10 Nm...
  • Page 15 Service data English –...

  • Page 16: Safety Equipment

    Safety equipment 6 Safety equipment List of contents Dismantling the chain brake ...................17 Assembling the chain brake ....................18 Dismantling the muffler ....................20 Assembling the muffler ....................20 6.5A Assembling the spike bumper ..................22 6.5B Replacing the chain catcher ...................22 Dismantling the start/stop switch ..................23 Assembling the start/stop control ..................23 Resistance test - stop function ..................23 Dismantling the throttle lockout, throttle and spring ............24...

  • Page 17: Dismantling The Chain Brake

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake Release the brake by moving the kickback guard backwards. Loosen the bar nut and remove the clutch cover, saw chain and bar. See Figure 1 Fig 1 Activate brake tension by pulling back the knee joint as shown in Figure 2.

  • Page 18: Assembling The Chain Brake

    Safety equipment Remove the knee joint with the attached brake band from its attachment in the clutch cover. Cleaning and checking • Clean and check carefully all components. Parts must be replaced if cracked or show signs of other defects. Always use original spare parts.
  • Page 19 Safety equipment Compress the spring with a wide screwdriver and press it down with your thumb. See Figure 9. Fit the cover over the brake spring and screw the screws back in place. See Figure 3 ”Dismantling the chain brake”. Fig 9 Tighten the chain brake by using the saw’s front hand guard as a tool.

  • Page 20: Dismantling The Muffler

    Safety equipment 6.3. Dismantling the muffler WARNING! Do not touch the muffler before it has cooled down. Risk of burns. Release the brake by moving the front hand guard backwards. Loosen the bar nut and remove the clutch cover, saw chain and bar. Fig 11 Loosen the screw holding the front hand guard.

  • Page 21: Assembling The Muffler

    Safety equipment Cleaning and checking • Clean and check all components carefully. Parts must be replaced if cracked or show signs of other defects. • Always use original spare parts. The spark arrestor mesh is best cleaned with a wire brush. The mesh must be replaced if it is damaged.

  • Page 22: A Assembling The Spike Bumper

    Safety equipment 6.5A Assembling the spike bumper The spike bumper is not fitted at the time of deliv- ery. When a spike bumper is fitted the first time, the washer fitted above the limiter cap must be removed. See Figure 19a. Release the brake by moving the kickback guard backwards.

  • Page 23: Dismantling The Start/Stop Switch

    Safety equipment 6.6 Dismantling the stop switch Dismantle the start/stop switch with a screwdriver. See Figure 20. Check that the stop switch is intact. Cleaning and checking Fig 20 • Clean and check carefully all components. Parts must be replaced if cracked or show signs of other defects.

  • Page 24: Dismantling The Throttle Lockout, Throttle And Spring

    Safety equipment 6.9 Dismantling the throttle lockout, throttle and spring Release the chain brake by moving the kickback guard backwards. Dismantle the clutch cover and front hand guard. See the ”Dismantling the muffler” chapter. Dismantle the handle half by loosening the screws as outlined in Figure 24.

  • Page 25: Assembling The Throttle Lockout, Throttle And Spring

    Safety equipment Cleaning and checking • Clean and check carefully all components. Parts must be replaced if cracked or show signs of other defects. Always use original spare parts. Check that the recoil spring is intact and • retains all its tension. Fig 28 6.10 Assembling the throttle lockout, throttle and spring...

  • Page 26: Replacing The Handle Insert

    Safety equipment 6.11 Replacing the handle insert To make the upper handle suit different hand sizes, the chain saw is supplied with three different han- dle insert sizes - M, L and XL. The L size is fitted when the chain saw is delivered. Release the chain brake by moving the kickback guard backwards.

  • Page 27: Assembling The Belt Eyelet

    Safety equipment 6.12 Assembling the belt eyelet The chain saw is fitted with two eyes at the rear edge of the chain saw housing, a rope eye and a belt attachment eye. The belt attachment eye is not fitted on delivery. Loosen the screw that holds the rope eye in place.

  • Page 28: Repair Instructions

    Repair instructions 7 Repair instructions List of contents Dismantling the starter ....................29 Changing a broken or worn starter cord .................30 Loading the recoil spring ....................31 Replacing a broken recoil spring ..................32 Assembling the starter ....................32 Testing the ignition module .....................32 Dismantling the ignition module and flywheel ..............33 Assembling the ignition module and flywheel ..............35 Dismantling the centrifugal clutch ...................36...

  • Page 29: Repair Instructions

    Repair instructions 7 Repair instructions 7.1 Dismantling the starter Loosen the screws that hold the starter against the crankcase and remove the starter. See Figure 1. Fig 1 Pull out the cord about 30 cm and release the tension in the recoil spring by letting the starter pulley slowly rotate anti-clockwise.

  • Page 30: Changing A Broken Or Worn Starter Cord

    Repair instructions 7.2 Replacing a broken or worn starter cord When the starter cord is worn and must be replaced, the tension in the recoil spring must be released. Pull out the starter cord about 30 cm. Release the tension in the recoil spring by letting the starter pulley rotate anti-clockwise.

  • Page 31: Loading The Recoil Spring

    Repair instructions Insert the starter cord through the starter handle 10mm and the spring guide. Make a simple knot with ap- proximately 10 mm of the free end protruding. See figure 4 (A). Turn the protruding end so that it is parallel with the cord before the knot and press the knot into po- sition in the spring guide.

  • Page 32: Replacing A Broken Recoil Spring

    Repair instructions 7.4 Replacing a broken recoil spring WARNING! Exercise care to ensure the spring does not fly out and cause personal injury. Wear protective goggles. Loosen the screws as outlined in Figure 8 and remove the starter pulley and the spring cassette. Replace the faulty spring cassette.

  • Page 33: Dismantling The Ignition Module And Flywheel

    Repair instructions 7.7 Dismantling the ignition module and flywheel Dismantle the following: • Starter and air guide rail. • Clutch cover. • Guide bar and saw chain. • Front hand guard. • Air filter cover and air filter. Fig 11 •...
  • Page 34 Repair instructions Pull the ignition module cables through the opening in the crankcase. See Figure 15b. Fig 15b Knock out a few of the pins in the tool if it does not match up with the flywheel. Press against the flywheel while the flywheel nut is loosened using a suitable socket spanner.

  • Page 35: Assembling The Ignition Module And Flywheel

    Repair instructions 7.8 Assembling the ignition module and the flywheel Fit the flywheel onto the crankshaft journal. Turn the flywheel until the key fits into the key slot on the axle. See figure 19 Tighten the nut and screw the pawls back on the flywheel. The ignition module must be fitted as follows: Fig 19 Pull the ignition module cabling through the...

  • Page 36: Dismantling The Centrifugal Clutch

    Repair instructions 7.9 Dismantling the centrifugal clutch Release the brake by moving the kickback guard backwards. Loosen the bar nut and remove the clutch cover, saw chain and bar. See Figure 23. Dismantle the air filter cover, remove the spark plug cap and unscrew the spark plug.

  • Page 37: Assembling The Centrifugal Clutch

    Repair instructions 7.10 Assembling the centrifugal clutch Hook the springs into the clutch shoes using a pliers. See Figure 27. Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 502 54 16-02 and a suitable socket spanner. Tightening torque of 20 Nm.

  • Page 38: Carburettor

    Repair instructions Cleaning and checking • Clean and check all parts carefully. Parts must be replaced if cracked or showing signs of other defects. Always use original spare parts. • Lubricate all moving parts with saw chain oil. Fig 32 7.12 Assembling the oil pump and screen Lower the oil filter in place and refit the oil pump...

  • Page 39: Carburettor

    Repair instructions 7.13 Carburettor WARNING! The fuel used for the chain saw has the following characteristics: 1. The liquid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is very flammable. Description The images for this description do not correspond to the carburettor on the chain saw.
  • Page 40 Repair instructions Function The carburettor functions differently in the following modes: • Cold start mode • Idle mode • Part throttle mode • Full throttle mode In cold start mode the choke valve, H, is completely shut. This increases the vacuum in the carburettor Fig 37 and fuel is easier to suck from all the diffuser jets, D, E and F.
  • Page 41 T540 XP Remove the AutoTune service connector from its attachment on the back of the filter holder (T540 XP). See Figure 42 See figure 42B regarding T540 XP II. Fig 42 T540 XP II Fig 42B Use a small flat screwdriver to unsnap the connector.
  • Page 42 Repair instructions Lift out the carburettor. Dismantle the pump cover (Q) above the metering unit and carefully remove the control diaphragm (R) with gasket. See Figure 44. Loosen the screw (S) and lift out the needle valve (U) with the lever arm (T), the axle and the spring. See Figure 44.
  • Page 43 Repair instructions Cleaning and checking WARNING! The fuel used for the chain saw has the following hazardous properties: The liquid and its fumes are poisonous. Can cause skin irritation. Is very flammable. Clean all units in clean petrol. WARNING! Never direct the compressed air jet towards the body.
  • Page 44 Repair instructions Assembling the carburettor Observe cleanliness when assembling the carburettor. The slightest contamination can cause malfunctions. 1. If throttle and choke valves with shafts, lever arms and springs have been removed, these must be assembled. The springs are tightened 1-2 turns.
  • Page 45 Repair instructions 6. Fit the control diaphragm (R) with gasket and cover (Q) with the bracket for the connector above the metering unit. See Figure 50. 7. Do a pressure test. 8. See figure 46 on how to assemble the AutoTune AB unit with gasket.
  • Page 46 See figure 51. Fig 52 T540 XP Fasten the AutoTune service connector to its at- tachment on the back of the filter holder (T540 XP). See figure 53. See figure 53b regarding T540 XP II Fig 53...

  • Page 47: Dismantling The Intake System

    Repair instructions 7.14 Dismantling the intake system Dismantle the following: • Clutch cover. • Front hand guard. • Air filter cover. • Air filter. • Air filter holder. Fig 55 • Carburettor. Loosen the screws holding the fuel pump attachment and the air valve. Remove the throttle cable from its attachment.
  • Page 48 Repair instructions Loosen the two lower screws holding the oil pump cover. See figure 60. Fig 60 Loosen the four screws holding the intake system. See Figure 61. Fig 61 The intake plate is fastened to the cylinder cover using the hooks (one on each side). See Figure 62. Fig 62 Loosen the oil pump cover from its groove and carefully remove the cylinder cover with the intake...

  • Page 49: Assembling The Intake System

    Repair instructions 7.15 Assembling the intake system Fit the intake system (B) and the air duct bellows (A) in the cylinder cover. See Figure 64. Fit the cylinder cover with the intake system over the cylinder as outlined in Figure 63. Then screw back the screws as outlined in Figures 61 and 60.

  • Page 50: Dismantling The Tank Unit

    Repair instructions 7.16 Dismantling the tank unit WARNING! The fuel used for the chain saw has the following hazardous properties: The liquid and its fumes are poisonous. Can cause skin irritation. Is very flammable. When dismantling the tank unit, see the ”Dismantling the intake system”...

  • Page 51: Aerating The Fuel Tank

    Repair instructions 7.18 Aerating the fuel tank The two-way valve has the following properties: • Checks opening pressure in both directions, which prevents a positive pressure or a vacuum developing in the fuel tank and impairing engine performance. This also prevents fuel leakage.

  • Page 52: Replacing The Fuel Filter

    Repair instructions 7.19 Replacing the fuel filter NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. When replacing the fuel filter, the old fuel filter must be taken out of the tank unit using the special 502 50 83-01 tool.

  • Page 53: Replacing The Fuel Hose

    Repair instructions NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. 7.22 Replacing the fuel hose The fuel hose is moulded (see Figure 72) and can only be removed from outside of the fuel tank.

  • Page 54: Dismantling The Piston And Cylinder

    Repair instructions 7.24 Dismantling the piston and cylinder Dismantle the following: • Tank unit. • Centrifugal clutch. • Muffler. • Intake system. Loosen the four cylinder screws and carefully pull out the cylinder and the gasket. See figure 77. NOTE! Take care to prevent any dirt and foreign particles from entering the crankcase.
  • Page 55 Repair instructions Cleaning and checking Clean all parts, and scrape off all gasket remains and soot from the following components: • The piston crown • Top of the cylinder bore (inside) • The cylinder exhaust port • The base of the cylinder and/or crankcase Check the following: •...

  • Page 56: Assembling The Piston And Cylinder

    Repair instructions 7.25 Assembling the piston and cylinder Oil the gudgeon pin bearing with two-stroke oil and fit it to the connecting rod. Fit the piston with the arrow facing the exhaust port, slide in the gudgeon pin and fit the circlips in place.

  • Page 57: Pressure Testing The Cylinder

    Repair instructions 7.26 Pressure testing the cylinder The following parts must be removed to pressure test the crankcase and cylinder: • Clutch cover • Filter cover. • Carburettor. • Air valve. Carry out pressure testing as follows: Fig 83 Fit the cover plate X-Torq intake (576 48 34-01) at the air valve and cover plate, intake (576 48 35- 01) at the carburettor using screws as outlined in Figure 85.
  • Page 58 Repair instructions Cleaning and checking Clean all parts and scrape off all gasket remains from the contact surfaces on the crankcase halves. Check the following: • That the big-end bearing does not have any radial play. Axial play is permitted. See Figure 85.

  • Page 59: Replacing The Crankshaft Bearing And Sealing Ring

    Repair instructions 7.28 Replacing the crankshaft bearing and sealing ring Use the 576 66 64-01 (A), 576 95 45-01 (F) and 725 23 80-51 (E) tools to assemble the crankcase bearing (B) and sealing ring. Fit the service tool as outlined in Figure 88.
  • Page 60 Repair instructions Place the guide pin in the crankcase half of the flywheel and fit a new gasket. Fit the 577 70 16-01 assembling tool to the crankshaft journal. See Figure 92. Put the crankshaft in position and fit the other crankcase half.

  • Page 61: Replacing The Bar Bolt

    Repair instructions 7.29 Replacing the bar bolt Replacing a bar bolt with intact crankcase Empty the chain oil tank. Knock in the old bar bolt from the outside so that it ends up in the chain oil tank. Remove the bar bolt from the chain oil tank. Attach a steel wire to the thread of the new bar bolt, thread the steel wire through the chain oil tank and out through the bar bolt opening in the crank-...

  • Page 62: Troubleshooting

    Repair instructions 7.30 Repairing damaged threads If threads on the chainsaw are worn, there are repair kits available. Damaged threads in the cylinder cover can be repaired using the 578 12 03-01 thread insert. Drill first with a 7.5 mm drill bit. Then screw in the thread insert using a suitable screw and spanner as shown in Figure 97.
  • Page 63 Troubleshooting 8 Troubleshooting List of contents Troubleshooting ......................64 Troubleshooting methods ....................65 English –...
  • Page 64 Troubleshooting 8.1 Troubleshooting The different faults which may occur on the chain saw are divided into four groups. Within each group possible operating faults are listed to the left while the probable fault alternatives are listed to the right. The most likely fault is listed first, etc. See separate instruction for AutoTune troubleshooting.
  • Page 65 Troubleshooting High speed Acceleration and retardation Does not run Blocked air filter Does not Blocked air filter at full throttle Tank venting clogged accelerate Tank venting clogged The fuel filter is clogged The fuel filter is clogged The fuel line is clogged The fuel line is clogged Loose or defective fuel hose Loose or defective fuel hose...
  • Page 66 115 46 60-26 2017W25...

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T540 xp ii

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