Husqvarna 390XP Workshop Manual
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Husqvarna 390XP Workshop Manual

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Workshop manual
390XP
English
English - 1

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Summary of Contents for Husqvarna 390XP

  • Page 1 Workshop manual 390XP English English - 1...

  • Page 2: Table Of Contents

    Workshop Manual 390XP Contents 1 Introduction and safety regulations ......3 2 Technical data ............6 3 Service tools .............. 8 4 Service data ............. 10 5 Chain brake ............. 12 6 Chain catcher ............15 7 Muffler ..............16 8 Start/stop switch .............

  • Page 3: Introduction And Safety Regulations

    Introduction and safety regulations 1 Introduction and safety regulations 1.5 Layout 1.1 General This Workshop Manual can be used in two different This Workshop Manual provides a comprehensive ways: description of how to troubleshoot, repair and test the chainsaw. A description of different safety measures that •...
  • Page 4 Introduction and safety regulations 1.1 General instructions 1.2 Special instructions WARNING! Read and understand the The workshop where chainsaw repairs are to be done following instructions to avoid personal must be equipped with safety equipment as set out in injury local regulations.
  • Page 5 Introduction and safety regulations 1.3 Symbols on the chainsaw 1.4 Symbols in this Workshop Manual The following symbols are found on the chainsaw casing. Choke This symbol indicates a risk of personal injury if instructions are not followed. Use protective gloves. Switch for hand grip heater Use protective goggles.

  • Page 6: Technical Data

    Technical data 2 Technical data Displacement Bore Stroke Max. power/rpm / cubic inch Ømm/Øinch mm/inch kW/hp / rpm 88 cm3/5.4 55mm/2.2” 3,7/1,5 4,8kW, 9600rpm Spark plug gap Ignition system Air gap Carburettor type mm/inch mm/inch 0,5/0,02 AM50 0.30mm/X WJ-116 Guide bar length Maximum chain speed Chain pitch Drive link...
  • Page 7 Technical data Idling speed Engage speed Max. speed Spark plug 390XP 2 700 3500 13000 NKG BPMR7A Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres/US pint Litres/US pint 390XP 0,90/1,9 4 - 20 cm3/min 0,50/1,1...

  • Page 8: Service Tools

    Service tools 3 Service tools 8 - English...
  • Page 9 Service tools The tools listed here are service tools intended for use on the chainsaw in question. In addition to these tools, a standard set of hand tools is required. Item Description Used for Article number Piston stop Locking the crankshaft 502 54 15-01 Cover plate, exhaust Sealing the exhaust port...

  • Page 10: Service Data

    Service data 4 Service data 4.5 ~ 5.5 Nm 4 mm 1 ~ 1.5 Nm 3 ~ 4 Nm 15 Nm 13 mm 1 ~ 2 Nm 1 ~ 2 Nm 1 ~ 2 Nm 12 ~ 14 Nm 5 mm 8 ~ 10 Nm 4 mm 20 Nm...
  • Page 11 Service data 0.5 ~ 1 Nm 6 ~ 7 Nm 4.5 ~ 5.5 Nm 4 mm 8 ~ 10 Nm 4 mm 15 Nm 19 mm 1 ~ 1.5 Nm 3 mm 8 ~ 10 Nm 4 mm 12 ~ 14 Nm 13 mm 0.5 ~ 1 Nm 4.5 ~ 5.5 Nm...

  • Page 12: Chain Brake

    Chain brake 5 Chain brake 5.1 Disassembly WARNING! Make sure the spring does not fly out and cause injury. Wear eye protection 1. Disassemble the chain and bar. Refer to the Operator’s manual. 2. Disassemble the centrifugal clutch. Refer to chapter Centrifugal clutch in the Workshop manual.
  • Page 13 Chain brake 7. Remove the spark plug and fit the piston stop. Remove the clutch with the clutch tool. Note the left-hand thread. Screw in the direction of the arrow. See fig. 5. Fig 5 Fig. 4 8. Remove the four screws (B) and the cover over the chain brake mechanism.
  • Page 14 Chain brake 5.3 Assembly WARNING! Make sure the spring does not fly out and cause injury. Wear eye protection Assemble the chain brake: Fit the toggle joint and brake strap. See fig. 9. Grease the moving parts of the toggle joint (J) and fit the unit on the chain saw.

  • Page 15: Chain Catcher

    Chain catcher 6 Chain catcher Fig. 10 6.1 Disassemble the chain catcher 1. Remove the clutch cover. 2. Disassemble the bar and chain. 6.2 Cleaning and inspection Inspect the chain catcher and replace it if it is damaged. See figure 1. 6.3 Assembly Fig.

  • Page 16: Muffler

    Muffler 7 Muffler 7.1 Disassembly WARNING! Do not touch the muffler until it has become cool. Risk of burn injuries. Remove the two lower M5 bolts and the two M6 bolts on the muffler. See fig. 1 Remove the gasket and cooling plate. See fig. 1 If the saw is fitted with a spark-arrester, remove it.

  • Page 17: Start/Stop Switch

    Start/stop switch 8 Start/stop switch Fig. 9 Fig. 9 8.1 Disassembly 1. Remove the stop switch with a screwdriver and detach the leads. See fig. 1. stop stop 8.2 Cleaning and inspection Fig. 10 Carefully clean and check all components. Parts must Fig.

  • Page 18: Throttle Trigger,Lockout And Spring

    Throttle trigger lockout, throttle trigger and spring 9 Throttle trigger lockout, throttle trigger and spring 9.1 Disassembly Remove the hand grip insert (C). See fig. 1. Remove the throttle lock pivot (A) with the help of a driver. See fig. 1. Press apart with a screwdriver or the like the throttle lock/control and take out the throttle lock from the recess in the hand grip.

  • Page 19: Starter

    Starter 10 Starter 10.1 Disassembly WARNING! Make sure the the spring is released on the starter pulley. it can come loose and cause personal injury. Remove the four bolts holding the starter to the crankcase and remove the starter. See fig. 1. Pull out the handle 20-30 cm and take out the cord Fig.
  • Page 20 Starter 10.3 Assembly If a new spring is to be fitted, place the new spring with steel wire so that the end loop comes over the peg (A) in starter pulley. See fig. 4. Press the spring down in the starter pulley and remove the wire.

  • Page 21: Electrical System

    Electrical system 11 Electrical system 11.1 Ignition system 11.1.1 Disassembly Remove the cylinder cover and starter unit. Release the blue lead (A) (which connects to the stop button) from the ignition module (B). See fig. 1. Remove the ignition cable (C) from the spark plug and release both cables from the cable guide (D), and remove the cable guide.
  • Page 22 Electrical system 11.1.3 Assembly To assemble the ignition system: Fit the flywheel on the spindle. Turn it gently until the key on the flywheel mates with the recess in the shaft. Fit the flywheel washer and nut (See fig. 5). Tighten the nut (Refer to ”4 Service data”...

  • Page 23: Carburettor Heater

    Electrical system 11.2 Hand grip heater and carburettor heater 390 Some chainsaws are fitted with hand grip heaters and carburettor heaters, and consist of the following parts: • Generator. • Switch. • Heating element in rear hand grip. • Front hand grip with heating element. •...
  • Page 24 Electrical system 11.2.2 Replacing the generator The following components must be removed before the generator can be replaced: A. Starter. Refer to Starter chapter. B. Flywheel. Refer to Flywheel chapter. 1. Remove the bolts for the rear damper element (A) and the travel inhibiting bolts (B).
  • Page 25 Fig. 18 Fig. 18 Electrical system 11.2.5 Replacing the front hand grip 1. Release the two cable clips beside the spring. See fig. 16. 2. Remove the five bolts (A, B, C and D) which hold the front hand grip. See fig. 15. 3.

  • Page 26: Centrifugal Clutch

    Centrifugal clutch 12 Centrifugal clutch 12.1 Disassembly When dismantling the centrifugal clutch the chain brake must be in the off position. Remove the cylinder cover and chain and bar. Refer to the Operators Manual. Remove the chain guide plate by unscrewing the bolt (A).
  • Page 27 Centrifugal clutch 12.2 Cleaning and inspection Clean all components and do a check of the following: min 3.5 mm The lining thickness on the clutch shoes must not be less than 3.5 mm at the most worn point. See fig. 5. To avoid imbalance all the clutch shoes must be replaced at the same time.

  • Page 28: Lubrication System

    Lubrication system 13 Lubrication system WARNING! Insufficient lubrication of the chain can result in the chain breaking, which can cause serious or even life-threatening injury. The lubrication system consists of the following parts: • Oil pump • Suction hose with filter •...
  • Page 29 Lubrication system Fig. 3 Remove the clip (D) and unscrew the adjuster screw (E). See fig. 4. Use a pair of pliers and push on the pump piston at (F) so that the cover plug (G) and pump piston (H) can be removed.
  • Page 30 (E) in fig 8. The table shows the number of turns from the home position for respective bar lengths. The table applies to Husqvarna chain oil. If a different oil is used the screw should be unscrewed an additional turn in the first two cases.
  • Page 31 Lubrication system English - 31...

  • Page 32: Carburettor

    Carburettor 14 Carburettor WARNING! The fuel used in the chainsaw has the following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 14.1 Description The illustrations in this description do not look like the carburettor on the chainsaw.
  • Page 33 Carburettor 14.3 Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In the cold start mode (fig. 4) the choke valve (D) is fully closed. This increases the vacuum in the carburettor so that fuel is sucked more easily from all the diffuser jets Fig.
  • Page 34 Carburettor 14.4 Disassemble the carburettor Remove the cylinder cover and air filter. Remove the carburettor control (A) by pushing it towards the carburettor and lifting. Unhook the throttle cable and remove the choke control. Remove the fuel pipe (B) and the impulse channel (C).
  • Page 35 Carburettor Fig. 12 Fig. 11 14.5 Cleaning and inspection Clean all units with clean petrol. WARNING! Do not direct the compressed air jet towards your body or any person when using compressed air. Air can go through the skin into the blood and result in mortal danger Use compressed air to dry the petrol on the components.
  • Page 36 Carburettor 14.6 Assembly Where no figure is referred to, see fig 11 in Disassemble the carburettor Maintain a high level of cleanliness when assembling the carburettor. The slightest contamination can result in operating problems. If the throttle and choke valves, together with levers and springs are removed, they must be refitted.

  • Page 37: Pressure Testing The Carburettor

    Carburettor Fit the control diaphragm (F) with packing and cover (E) on the metering unit. See fig. 16. Do a pressure test. 14.7 Pressure testing the carburettor Fig. 16 Pressure testing must be done with the carburettor fully assembled. Testing must always be done after the car- burettor has been repaired, but it can also be done as trouble shooting before disassembling the carburettor.

  • Page 38: Carburettor Adjustment

    Carburettor 14.9 Carburettor adjustment WARNING! The guide bar, saw chain and clutch cover must be fitted before the chain saw is started, or the clutch can come loose causing personal injury. WARNING! Wear ear protection when making adjustments with the engine running. WARNING! Do not use the chainsaw until it has been adjusted so that the saw chain is still...

  • Page 39: Tank Unit

    Tank unit 15 Tank unit WARNING! The fuel used in the chainsaw has the following hazardous properties: The fluid and its fumes are poisonous. Can cause skin irritation. Is highly inflammable. 15.1 Disassembly NOTE! Fluted pliers may not be used with the fuel hose.
  • Page 40 Fig. 1 Tank unit 15.3 Assembly If the chainsaw is fitted with hand grip heating, fit the heating element if it has been removed. To fit a new fuel pipe: • Lightly oil in one half of the new fuel pipe. •...

  • Page 41: Anti-Vibration System

    Anti-vibration system 16 Anti-vibration system WARNING! The fuel used in the chainsaw has the following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 16.1 Disassembly Dismantle the following parts: •...

  • Page 42: Piston And Cylinder

    Piston and cylinder 17 Piston and cylinder 17.1 Disassembly CAUTION! Be careful so that dirt and unwanted materials do not get into the crankcase. Disassemble the following parts: • Cylinder cover. • Spark plug. • Carburettor. • Muffler. Unscrew the anti-vibration spring (B) from the cylinder.
  • Page 43 Piston and cylinder 4. That the piston ring is not burnt into its groove. 5. Measure the wear on the piston ring by placing it in the cylinder and measuring the gap. See figure 4. Max. 1 mm The gap must not exceed 1 mm. 6.
  • Page 44 Piston and cylinder 17.3 Assembly To assemble the piston and cylinder. Lubricate the needle bearing and fit it in the connecting rod’s smallest end. Replace the piston with the arrow facing the exhaust port. See fig. 8. Slide in the gudgeon pin and fit the circlip.
  • Page 45 Piston and cylinder 17.4 Leakage testing The following parts must be removed to pressure test the crankcase and cylinder: • Carburettor. • Muffler. To do a pressure test: Remove the support ring in the intake manifold. Fit cover plate (Refer to pos. 2a ”3 Service tools” on page 8) with M4x15 mm bolt on the intake manifold.

  • Page 46: Crankcase And Crankshaft

    Crankcase and crankshaft 18 Crankcase and crankshaft 18.1 Disassembly CAUTION! Be careful so that dirt and unwanted materials do not get into the crankcase. Fig. 1 WARNING! The crankcase halves are hot and can cause burn injuries. Wear protective gloves. Before the crankcase can be separated the following parts must be disassembled: •...
  • Page 47 Crankcase and crankshaft Fig. 2 Fit tool 4310048-67 as shown in fig. 4 and remove the crankcase half on the clutch side. Remove the crankcase half on the flywheel side in the same way as item 4 above. Fig. 4 Fig.
  • Page 48 Crankcase and crankshaft Fig. 7 That the bearing surfaces for the little-end do not have any score marks or are discoloured. See fig. 8. That the crankshaft bearings do not have any play or dissonance. That the surfaces of the seals to the crankshaft are not worn and that the rubber has not hardened.
  • Page 49 Crankcase and crankshaft 4. Place the guide pegs in the crankcase half of the clutch side, and grease in and insert the gasket. See fig. 12. Fig. 12 Fig. 12 Fig. 12 Fig. 12 5. Use tool (Refer to “3 Service tools” on page 8, Pos.
  • Page 50 Crankcase and crankshaft 18.4 Seals 1. To replace the seals on the crank shaft, remove the following parts first: On the flywheel side: • Starter • Flywheel • Generator, where appropriate On the clutch side: • Chain and bar. Refer to Operators manual. •...

  • Page 51: Bar Bolts

    Bar bolts 19 Bar bolts 19.2 Disassembly 1. Drain the chain oil. 2. Push in the old bar bolt from outside so that it drops Fig. 15 in the oil tank. 3. Remove the bolt from the oil tank. 19.3 Cleaning and inspection Clean and inspect all parts.

  • Page 52: Troubleshooting

    Troubleshooting 20 Troubleshooting 20.1 General troubleshooting Uneven idling Blocked fuel filter Blocked fuel line The different faults which can occur on the chainsaw are Leaking inlet hose (rubber) divided into four groups. Within each group Loose carburettor mounting possible operating faults are listed to the left while the Worn throttle valve axle probable fault alternatives are listed to the right.

  • Page 53: Troubleshooting Methods

    Troubleshooting Low power Tank venting clogged Too rich acceleration Adjust the L-screw Blocked fuel filter Adjust the H-screw Impulse channel leaking Blocked air filter Blocked impulse channel Faulty pump diaphragm The cover on the carburettor Faulty diffuser jet pump side is loose Faulty pump diaphragm Blocked air filter Control system sticking...
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