Page 1 Husqvarna Chain Saws Workshop Manual 101 88 55-26...
Page 2: Table Of Contents
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 .......
Page 3: Introduction
For specific procedures special tools are re- 272XP quired. In this workshop manual, all the service 268K tools required are listed. Use of the tools is 272K described in appropriate sections. 272S Always use Husqvarna original: 281XP • Spare parts 288XP • Service tools 242XP •...
Page 4 INTRODUCTION Dismantling and reassembly of the entire chain saw This workshop manual can be used in two different ways: When the entire chain saw is to be dismantled and reassembled, proceed as follows: • Repair of a specific sub-assembly • Dismantling and reassembly of the entire chain Refer to page 57, which deals with the Starter and carry out the instructions...
Page 5: Safety Regulations
Make sure that the starter recoil other equipment or accessories and spare spring does not fly out and cause parts not approved by Husqvarna can personal injury. Release the spring result in non compliance with these safety tension before the cord pulley is removed.
Page 6: Technical Data
TECHNICAL DATA Displacement Bore Stroke Max. power at r/min 38.0 32.0 9000 40.0 32.0 9000 40.0 32.0 9000 42.0 30.0 9300 42.0 32.0 9000 45.0 32.0 9000 Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239 0.5/ .02...
Page 7 TECHNICAL DATA Idling speed Engagement speed Max. speed Spark plug r/min r/min r/min Champion 3000 4500 13000 RCJ 7 Y 2500 3600 12500 RCJ 7 Y 3000 4500 13000 RCJ 7 Y 2700 3800 14500 RCJ 7 Y 2500 3600 12500 RCJ 7 Y 2500...
Page 8 TECHNICAL DATA Displacement Bore Stroke Max. power at r/min 46.0 32.0 9000 48.0 34.0 8300 242XP 42.0 30.0 9900 44.0 30.0 9000 254XP 45.0 34.0 9300 46.0 34.0 9000 Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170...
Page 9 TECHNICAL DATA Idling speed Engagement speed Max. speed Spark plug r/min r/min r/min Champion 2500 3700 12500 RCJ 7 Y 2500 3700 12000 RCJ 7 Y 242XP 2700 3900 15500 RCJ 7 Y 2700 3900 15000 RCJ 7 Y 254XP 2700 3700 13800...
Page 10 TECHNICAL DATA Displacemennt Bore Stroke Max. power at r/min 262XP 48.0 34.0 9600 50.0 34.0 9000 272XP 52.0 34.0 9300 268K 50.0 34.0 9000 272K 52.0 34.0 9300 272S 52.0 34.0 9300 Spark plug gap Ignition system Air gap Carburettor mm/inches mm/inches 262XP...
Page 11 TECHNICAL DATA Idling speed Engagement speed Max. speed Spark plug r/min r/min r/min Champion 262XP 2700 3400 13500 RCJ 7 Y 2500 3500 12500 RCJ 7 Y 272XP 2500 3500 13500 RCJ 7 Y 268K 2500 3500 10000 RCJ 7 Y 272K 2500 3500...
Page 12 Chain speed Chain pitch Drive link gauge cm/inches inches mm/inches 281XP 38-71/15-28 20.0/9000 rpm 1.5/ .058 288XP 38-71/15-28 20.7/9300 rpm 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 – English...
Page 13 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...
Page 14: Tools
502 50 88-01 5 mm 502 50 87-01 4 mm 502 50 86-01 3 mm 502 71 13-01 504 98 26-01 (36, 41, 40, 45) 502 50 06-01 502 51 34-02 (0,3 mm) 502 51 91-01 (0,5 mm) 502 50 83-01...
Page 15 TOOLS Tools for saws 36 and 41 Tools for saws 40, 45, 51 and 55 4 mm 3 mm; 4 mm; 5 mm 8 mm 8 mm; 10 mm 502 50 33-01 502 50 33-01 505 26 79-12 40 > 910 1116 45 >...
Page 16 TOOLS Tools for saws 42, 242 and 246 Tools for saws 254, 257 and 262 3 mm; 4 mm 3 mm; 4 mm 8 mm 8 mm 502 50 33-01 502 50 33-01 *compl 502 51 49-02 *compl 502 51 49-02 502 51 49-01* 502 51 49-01*...
Page 17 Tools for saws 61, 268 and 272 Tools for saws 281 and 288 3 mm; 4 mm; 3/16" 3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm) 8 mm 502 71 36-01 (4 mm) 502 50 33-01 502 50 33-01...
Page 18 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 26-01* 504 90 90-01 502 50 82-01 502 50 52-01 502 50 30-08 502 50 66-02...
Page 19 502 71 13-01 Test spark plug 502 50 31-01 Puller 502 71 14-01 Tachometer 502 50 33-01 Piston stop 502 71 36-01 Allen key 502 50 37-01 Vacuum gauge 502 50 38-01 Pressure gauge 502 71 38-01 Cover plate 502 50 45-01...
Page 20: Service Data
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).
Page 21 SERVICE DATA English –...
Page 22 SERVICE DATA Saws 42, 242 and 246 8-10 42 246 42 246 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).
Page 23 SERVICE DATA English –...
Page 24 SERVICE DATA Saws 40 and 45 25-35 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). 10-12 –...
Page 25 SERVICE DATA 8-10 25-30 English –...
Page 26: Service Data (Saws 51/55)
SERVICE DATA Saws 51 and 55 30-40 1,5-2 8-10 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). –...
Page 27 SERVICE DATA 8-10 12-14 English –...
Page 28 SERVICE DATA Saws 254 and 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). –...
Page 29 SERVICE DATA English –...
Page 30 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). – English...
Page 31 SERVICE DATA English –...
Page 32 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). –...
Page 33 SERVICE DATA 268 272 English –...
Page 34 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). –...
Page 35 SERVICE DATA English –...
Page 36 SERVICE DATA Saw 394 10-12 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). – English...
Page 37 SERVICE DATA 20-22,5 10-12 12-14 30-40 English –...
Page 38 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). – English...
Page 39 SERVICE DATA English –...
Page 40: Trouble Shooting
TROUBLE SHOOTING Trouble shooting schematic Faults that can develop on the chain saw are divided into four groups as follows. In each cat- egory, 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.
Page 41 TROUBLE SHOOTING Acceleration and retardation High rpm Adjust H-screw Will not run at full Does not accelerate Adjust L-screw Blocked air filter throttle Adjust H-screw Blocked fuel tankbreather Blocked air filter Blocked fuel filter Blocked fuel tankbreather Fuel line blocked Blocked fuel filter Loose or damaged fuel line Fuel line blocked...
Page 42: Safety Equipment
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.
Page 43 Use a punch to knock out the pin holding the knee link. Remove the screw that holds the fixed end of the band. 36, 41, 61, 268, 40, 42, 45, 51, 272, 281 and 288 242, 246, 55, 254, 257, 262 and 394...
Page 44: Cleaning And Inspection
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 3120 Fit the screw that holds the band's fixed end.
Page 45 SAFETY EQUIPMENT All saws except 3120 3120 Fit the spring and screw onto the pressure Slide the spring over the knee link's stud and rod on the brake band. press down the opposite end of the spring into Note! Plastic sleeve. its recess.
Page 46 SAFETY EQUIPMENT 3120 All saws except 3120 Carefully tighten the vice until the hole for the tubular pin and the ratchet align. Fit the hand guard, the two bushings and the screw. Carefully knock in the pin. Fit the cylindrical pin. Pull back the hand guard so that the brake is Check the chain brake as described on the not actuated.
Page 47 SAFETY EQUIPMENT Checking brake operation WARNING! After repair, the chain brake must be checked as set out in the following instructions. The engine should not be running during the test. Test that the chain brake comes on as follows: Hold the chain saw above a firm surface. The distance between the bar and the surface are shown in the table below.
Page 48: Chain Catcher
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: •...
Page 49 Remove the muffler, gasket and cooling plate (B) if the saw is so equipped. If the saw is equipped with a spark arrester (C), remove this. Saw 242 Cat Saws 36 and 41 Dismantle the muffler as shown in the figure to the right. WARNING!
Page 50 Assembly Assemble the muffler and fit to the cylinder. Tightening torque, see page Clean all contact surfaces. Saws 36 and 41 Other saws If the saw is equipped with a spark arrester (C), fit this. WARNING! The coating on and in the cata-...
Page 51: Stop Switch
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.
Page 52: Throttle Lock
Saws 61, 268, 268K, using a punch. See continuation on next 272XP, 272K, 272S, page. 281XP, 288XP and 394. Saws 36, 41, 42, 55, 242XP, 246, 51, Saw 394 Saws 61, 268, 272XP, 272K, 254XP, 257 and 272S, 281XP and 288XP. 262XP.
Page 53 SAFETY EQUIPMENT Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP, Saws 61, 268, 268K, 272XP, 272K, 272S, 257 and 262XP. 281XP, 288XP and 394. Remove the rubber element (A). Slide out Dismantle the throttle pin (B) by using a the throttle pin (B) and lift out the throttle arm punch.
Page 54 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.
Page 55 SAFETY EQUIPMENT Assembly Saws 36, 40, 41, 45, 42, WARNING! 242XP, 246, 51, 55, Other saws. The fuel used in the chain saw 254XP, 257 and 262XP. poses the following hazards: The liquid and its vapours poisonous. Can cause skin irritation.
Page 56 SAFETY EQUIPMENT Saws 61, 268, 268K, Saws 36, 41, 42, 242XP, Saw 3120. 272XP, 272K, 272S, 246, 51, 55, 254XP, 257, 281XP and 288XP. 262XP and 394. Fit the throttle lock and Fit the throttle arm and Fit the three pins that hold spring.
Page 57: Starter
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.
Page 58 STARTER Cleaning and Inspection Clean all parts and check the following: WARNING! The starter cord. Ensure that the spring does not fly out and cause personal injury! The dogs in the starter pulley. That the pawls on the flywheel are OK, and spring back towards the centre and move freely.
Page 59 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. 42, 242, 246, 51, 55, 254, 36 and 41. 61, 268, 272, 281 and 288. 257,262, 394 and 3120.
Page 60 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.
Page 61: Electrical System
Dismantling Remove the cylinder cover and the starter unit. Remove the spark plug and fit the piston stop. Saws 36 and 41. Loosen the cable that runs to the stop switch from the ignition module. Release the cables from the guide rail and remove the guide rail.
Page 62 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.
Page 63 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.
Page 64 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.
Page 65: Handle Heating
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.
Page 66 ELECTRICAL SYSTEM Checking the generator Check the handle loop Connect the ohm meter to the cylinder Connect the ohm meter to points B and C. (point A1) and point B. The ohm meter The ohm meter should read 3-4 ohm. should read 0.9-1.3 ohm.
Page 67: Centrifugal Clutch
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 Saws with one Saws with three C-springs.
Page 68 CENTRIFUGAL CLUTCH Cleaning and Inspection Clean all parts and inspect the following: Clutch shoes Clutch shoes without chamfers. with chamfers. That measurement A is not below 1 mm. That measurement B is not under 1 mm. Check that there is no play between the clutch shoe and clutch hub Check for wear on the chain sprocket.
Page 69 (A) and fit the help of circlip pliers. spring. Using a spanner secure the clutch centre. On saws 36 and 41 use service tool no. 530 03 11-12. Note! Left-hand thread. Fit the chain and bar. See the operating instruc- Remove the piston stop and fit the spark tions.
Page 70: Lubrication System
• Centrifugal clutch. See page 67. Saw 3120. See page 72 Other saws. Saws 36, 40, 41, 45, 51 and 55. 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.
Page 71 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.
Page 72 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.
Page 73 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 51 and 55. Saws 36, 40, 41 and 45. Undo the two bolts and lift off the pump Lift off the pump and the upper seal.
Page 74 LUBRICATION SYSTEM 40/45 36/41 A. Lower seal. B. Pump cylinder. C. Upper seal. D. Chain guide plate. E. Pump housing. Pump piston. G. Worm gear. 50/51 – English...
Page 75 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.
Page 76 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.
Page 77 LUBRICATION SYSTEM Assembling the worm gear Screw the worm gear into the dismantling On those saws where the oil pump worm tool and press the worm gear onto the gear is pressed on the crankshaft. crankshaft until it bottoms against the collar.
Page 78 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.
Page 79 LUBRICATION SYSTEM Saw 3120. Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts 5. Fit lever arm (F). 2. Fit the seal (C). 6. Fit units (B-F-G) with spring (H) and 3. Fit the pump piston (D) with spring. screw in position using screws (A) and Press in the piston and hold it in latch (J).
Page 80 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.
Page 81 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. A. Lower seal. 2. Fit the worm gear (G) on the B. Pump cylinder. crankshaft, if necessary C.
Page 82 LUBRICATION SYSTEM Saws 36, 40, 41 and 45. Saws 51 and 55. Fit the oil pump in the crankcase and fit Fit the oil pump in the crankcase, tighten the upper seal. the two bolts and fit the upper seal.
Page 83: Carburettor
CARBURETTOR Description The diagrams in this description do not WARNING! correspond with the carburettor fitted on The fuel used in the chain saw poses the chain saws. They serve only to show the following hazards: the principles of design and operation. 1.
Page 84 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).
Page 85 CARBURETTOR Dismantling 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. 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.
Page 86 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.
Page 87 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.
Page 88 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.
Page 89 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.
Page 90 CARBURETTOR Cleaning and Inspection 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. Clean all components in petrol. Wear gloves or skin protection cream. WARNING! Never direct the compressed air jet towards the body.
Page 91 CARBURETTOR Assembly Refer to the carburettor in question on the WARNING! next eight pages. A pressure test, see The fuel used in the chain saw page 100, should be carried out after poses the following hazards: 1. The fluid and its vapours are assembling and before the carburettor is poisonous.
Page 92 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.
Page 93 CARBURETTOR Tillotson HS 255 B Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating prob- lems. 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.
Page 94 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.
Page 95 CARBURETTOR Walbro HDA och HD Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating prob- lems. 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.
Page 96 CARBURETTOR Walbro WJ Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating prob- lems. 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.
Page 97 CARBURETTOR Walbro WG Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating prob- lems. 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.
Page 98 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.
Page 99 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.
Page 100 CARBURETTOR Pressure testing WARNING! The fuel used in the chain saw poses the following hazards: Pressure testing should be carried out with the 1. The liquid and its vapours are carburettor fully assembled. Testing should poisonous. always be carried out after the carburettor has 2.
Page 101: Air Filter
Compressed air at a high pressure can damage the foam. Oiling Oil the filter carefully. It is extremely impor- tant that the entire filter is saturated with oil. Use HUSQVARNA oil no. 503 4773-01. The bottle holds 0.1l, which is sufficient for three applications. English –...
Page 102 AIR FILTER Main filter The main filter is a paper filter and is accessible under the cover (B). This filter should be replaced/cleaned when the saw’s power de- creases or after 1-2 weeks. The filter is cleaned either by shaking or carefully blowing clean with compressed air.
Page 103: Tank Unit
TANK UNIT Dismantling WARNING! Empty the tank and dismantle the cylinder The fuel used in the chain saw poses the following hazards: cover as well as the bar and chain. 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3.
Page 104 TANK UNIT Bolts placed at Bolts placed at A, D, F, K A, D, F, L Has no tank unit 262XP A, D, F, L A, D, F, K A, C, D, F, G, K A, D (under a cover) F, G, L 268K A, C, D, F, G, K Has no tank unit...
Page 105 TANK UNIT Assembly If a new fuel pipe is to be fitted proceed as 3. Twist the hose so that it takes on the same follows: angle to the carburettor and let the hose 1. Measure the length of the old hose out- protrude as much as the old hose did.
Page 106: Anti-Vibration System
ANTI-VIBRATION SYSTEM Description The anti-vibration system reduces the vibra- tions which pass from the engine and cutting equipment to the handles. The anti-vibration system consists either of rubber elements or coil springs. The system’s movement limitation consists of side absorbers and/or stop screws. Dismantling The tank unit must be removed from the engine sub-assembly to access the anti-vibration system.
Page 107 ANTI-VIBRATION SYSTEM Assembly Fit the rubber stop with the help of a wire or the like. Fitting the anti-vibration system’s side absorber. Fitting the anti-vibration system’s damper element. Tightening torques, see the ”Service data” for respective saws. Saw 394 Saws 40, 45 and 3120 Other saws Fit the rubber element using the tools Slide in the spring and its holder.
Page 108: Piston And Cylinder
• Cylinder cover. See operating instructions. • Carburettor. • Spark plug. See operating instructions. • Muffler. Saws 36, 40, 41 and 45. Other saws On saw 394, disconnect the anti-vibration Dismantle the insulation plate between the spring (A) from the cylinder.
Page 109 PISTON AND CYLINDER Cleaning and Inspection Clean all parts, scrape off any gasket residue remove carbon deposits from the following areas: 1. The piston crown. 2. The top of the cylinder bore. 3. The cylinder exhaust port. 4. The decompression valve channel. Check the following: 1.
Page 110: Faults And Causes
PISTON AND CYLINDER On saws 40 and 45, check the rubber sealing on the shaft seat. Change the shaft seat, if necessary. Faults and causes Score marks on the piston. 1. Incorrect carburettor setting max. speed too high 2. Too low octane fuel. 3.
Page 111 Refit the piston with the arrow facing the exhaust port. Slide in the gudgeon pin and fit the circlip. Other saws Saws 36, 40, 41 and 45 Fit a new cylinder gasket Oil the piston and piston ring. Compress the piston ring either by hand or by using tool 502 50 70-01.
Page 112 PISTON AND CYLINDER Other saws Saws 36, 40, 41 and 45. Fit the four bolts under the crankcase. Tightening torque, see ”Service data”. Saws 40 and 45. Saws 36 and 41. Fit the four cylinder bolts (B). On saw 394, connect the anti-vibration spring (A) to the cylinder.
Page 113 PISTON AND CYLINDER Pressure testing Decompression valve Test the decompression valve as follows. 1. Connect the tool 502 50 38-01 to the decompression valve 2. Pump up the pressure to 80 kPa (0.8 bar). 3. Wait 30 seconds. 4. The pressure should not drop below 60 kPa (0.6 bar).
Page 114: Crankcase And Crankshaft
Piston and cylinder. See page 108. Electrical system. See page 61. Tank unit. See page 103. Other saws Saws 36, 40, 41 and 45. See next page. Saw 394. NOTE! Ensure that no dirt or foreign particles enter the bearings.
Page 115 Risk of burns. Wear protec- tive gloves. Remove all rubber and plastic components from the crankcase halves. Saws 36 and 41. Saws 40 and 45. Heat the crankcase half in question to 200°C. Wear protective gloves and knock the...
Page 116 CRANKCASE AND CRANKSHAFT Cleaning and Inspection NOTE! Ensure no dirt or foreign particles enter the bearings, if fitted in the crankcase halves. Clean all parts and scrape of any gasket residue from the mating surfaces of the crankcase halves. Check the following: That the big end bearing does not have any radial play.
Page 117 CRANKCASE AND CRANKSHAFT Assembly Saws 40 and 45. Other saws Saws 36 and 41. See page 120. Fit the bearing and seals on the crankshaft. WARNING! The crankcase halves can be hot. Grease the seals. Risk of burns. Wear protective Continue assembly as described on gloves.
Page 118 CRANKCASE AND CRANKSHAFT Other saws. Saw 40 and 45. NOTE! See page 120. Ensure that the connecting rod does not jam against the crankcase when the crankcase and crankshaft are assembled. Grease and fit a new crankcase gasket (A). Using the assembly tool for the chain saw in Check that the guide pin (B) is in position and question assemble the crankshaft in the fit the other crankcase half.
Page 119 CRANKCASE AND CRANKSHAFT Saw 40 and 45. Other saws. Fit the crankcase bolts. Tighten crosswise See next page. with the torque set out in the ”Service data”. Tighten the bolts closest to the crankshaft first. NOTE! Ensure excess gasket material does not fall into the crankcase.
Page 120 CRANKCASE AND CRANKSHAFT Saws 40 and 45. NOTE! Ensure that dirt and foreign particles do not enter the bearing. Fit the bearing on the crankshaft by using the assembly tool. See ”Tools”. Check the shaft seat’s sealing (A). Fit the shaft seat over the bearing and join the shaft seat at (B).
Page 121 CRANKCASE AND CRANKSHAFT Bar bolts When changing the bar bolts on all saws except 40 and 45 proceed as follows: 1. Drain the chain oil. 2. Knock through the old bar bolt so that it falls in the oil tank. 3.
Page 122 CRANKCASE AND CRANKSHAFT Changing the seals This section describes how to change the seals without splitting the crankcase. Dismantling Before dismantling the seals remove the following parts: On the starter side: • Starter • Flywheel • Generator (if fitted) On the clutch side: •...
Page 123 CRANKCASE AND CRANKSHAFT Assembly Seal assembly in the oil pump 1. Place the oil pump on a sleeve (A) with an inner diameter greater than the seal’s outer diameter. 2. Fit the seal (B) using the assembly punch so that the surfaces (C), are level.
Page 124 CRANKCASE AND CRANKSHAFT Assembly positions starter side Measurement A should be as in the table below for resp. saws (Under the crankcase plane). 61, 268 4-4.5 mm 2 mm 281, 288 3.5 mm Measurement B should be as in the table below for resp.

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