Workshop manual Husqvarna 357XP/G and 359/G Contents Introduction ............2 Safety regulations ..........3 General instructions ........... 3 Special instructions ..........3 Special tools ............4 Technical data ............6 Construction and function ........8 Carburettor ............8 Troubleshooting ..........10 Repair instructions ..........
Removal/Dismantling Cleaning and inspection Refitting/Reassembly This workshop manual covers the following chainsaw models: Dismantling and reassembling the entire 357XP/G chainsaw 359/G If the entire chainsaw is to be dismantled, follow the instructions under the heading “Removal/ Dismantling”. Work through the manual and follow the instruc- tions given in each section under the heading “Removal/Dismantling”.
Safety regulations General instructions Special instructions This workshop manual gives detailed instructions The fuel that is used in a chainsaw poses the on how to troubleshoot, repair and test a chainsaw. following hazards: This section also describes the various safety precautions that should be taken when carrying out •...
Construction and function Carburettor The carburettor works in different ways depending on the setting: The carburettor consists of three sub-systems: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode • The metering unit (A) which contains the jets and the fuel control mechanism.
Construction and function In part throttle mode the throttle valve (F) is par- tially open. Fuel is supplied through the diffuser jets (E). In full throttle mode both valves are open and fuel is supplied through all the diffuser jets (E). English –...
Troubleshooting The various faults that can affect a chainsaw are divided into four groups. In each group the likely symp- toms are given on the left and possible causes are listed on the right. The most likely faults are given first, and so on.
Troubleshooting Acceleration and retardation High rpm Adjust H screw Will not run Does not Adjust L screw Blocked air filter at full throttle accelerate Adjust H screw Blocked fuel tank vent Blocked air filter Blocked fuel filter Blocked fuel tank vent Fuel line blocked Blocked fuel filter Loose or damaged fuel hose...
Repair instructions Chain brake – dismantling WARNING! Make sure the spring does not fly out and cause injury. Wear eye protection. Disengage the brake by pushing the kickback Remove the screws and carefully remove the cover guard backwards. Unscrew the guide bar bolts and from the chain brake spring.
Repair instructions Chain brake – reassembly Bolt the elbow joint to the brake band and tighten to a torque of 1–1.5 Nm. Tension the brake spring by using the kickback Locate the elbow joint and connected brake band guard from the saw as a tool. Engage it with the in their recesses in the clutch cover.
Repair instructions Silencer – removal Silencer – refitting WARNING! If the saw is equipped with a spark arrestor mesh Do not touch the silencer until it this should be fitted first. has cooled down, otherwise you may burn yourself. Refit •...
Repair instructions Stop switch – removal Remove the cylinder cover. Carefully prise the stop switch’s upper mounting off the air filter holder while lifting the switch to release it from the lower mounting. Release the clip and remove the air filter. Discon- nect both leads from the stop plate and stop switch.
Repair instructions Stop switch – refitting Choke control – removal Remove the cylinder cover, air filter and stop switch. Disconnect the fuel hose from the carburet- tor. NOTE! Do not use knurled pliers to disconnect or reconnect the fuel hose. This could dam- age the hose and lead to leakage or frac- ture.
Repair instructions Choke control – refitting First reattach the choke control to the air filter, then press it onto the carburettor so that the clips engage. Then refit: • stop switch • carburettor into its rubber mountings • throttle pushrod into the fuel tank and connect to throttle lever.
Repair instructions Hand grip heater on model 357XP/G and 359/G – removal No heating or heating only in front hand grip • Front hand grip – troubleshooting First insert the rear edge of the throttle trigger into the tank. Then push/clip the front edge into the two clips on the tank with the aid of a combination tool, for example.
Repair instructions • Generator – troubleshooting Heater element and rear hand grip – removal Remove the cylinder cover and cover from the Remove the cylinder cover, hand grip cover, hand front hand grip. Disconnect the black lead from the grip and right-hand stop. generator and connect a multimeter between it and a clean area on the cylinder.
Repair instructions Hand grip heater on model 357XP/G Starter assembly – removal and 359/G – refitting Feed the leads into the rear hand grip and insert the heater element in the hand grip. Screw in the two bolts through the right side of the hand grip to secure the heater.
Repair instructions Cleaning and inspection Cleaning and inspection: Clean the parts and check the following: • Clean and inspect all parts carefully. If there are any cracks or other defects replace the dam- • The starter cord. aged parts with new ones. Lubricate the return •...
Repair instructions Ignition module – testing If there is a fault in the ignition system the ignition module must be tested before the ignition system is removed. Fit a new recoil spring. Lubricate the recoil spring with light oil. Fit the bolt through the centre of the pulley and tighten to a torque of 2–3 Nm.
• Check that the flywheel is not cracked or dam- aged in any other way. Replacing the generator, model 357XP/G and 359/G Remove the cylinder cover. Disconnect the HT lead, remove the spark plug and fit piston stop 502 54 15- If replacing the ignition module, disconnect its leads 01 in its place.
Repair instructions Ignition module and flywheel – refitting Unscrew the two bolts from the generator but leave the generator in place. Remove the fuel hose and throttle pushrod from the carburettor. Unbolt the rear tank mounting from the crankcase, i.e. the rear vibration damping spring, and both stops.
Repair instructions Centrifugal clutch – removal Then refit: • cable guide and press the leads into position Remove the cylinder cover. Disengage the chain • HT lead brake by pushing the kickback guard backwards. • starter assembly, tighten to a torque of 2.5–3.5 Undo the guide bar bolts and remove the clutch cover, chain and guide bar.
Repair instructions Centrifugal clutch – refitting Unbolt the clutch by turning the nut clockwise using tool 502 52 22-02. NOTE! Handle the clutch springs carefully. If they are opened up too much they could damage the saw. Insert the clutch springs in the shoes using circlip pliers and a screwdriver.
Repair instructions Oil pump – removal Empty and clean the oil tank. Remove the chain guide plate. Remove the cylinder cover. Disengage the chain brake by pushing the kickback guard backwards. Undo the guide bar bolts and remove the clutch cover, chain and guide bar.
Repair instructions Remove the pin (B) from the adjuster screw, using a small drift to press it out. Press in the pump piston (C) so that the adjuster screw (D) can be removed. Remove the pump piston. Cleaning and inspection •...
Repair instructions Carburettor – removal Fit the clutch and tighten anticlockwise as far as it will go. Then tighten to a torque of at least 20 Nm using tool 502 52 22-02. Remove the piston stop. Fit the spark plug, tighten- ing it to a torque of 15 Nm, then connect the HT lead.
Repair instructions Carburettor – dismantling NOTE! Do not use knurled pliers to disconnect or reconnect the fuel hose. This could dam- age the hose and lead to leakage or fracture. Disconnect the fuel hose from the carburettor. Remove the rubber inlet manifold, using pliers to lift it upwards.
Repair instructions Cleaning and inspection If the throttle and choke butterflies and their Clean all the carburettor components in petrol. Use spindles were removed, these must be refitted. an airline to dry off the petrol from all components. Lubricate the spindle bearings with light oil. Blow through all the channels in the carburettor body and check that they are not blocked.
Repair instructions Carburettor – pressure testing Carburettor – refitting Pressure testing should be carried out with the carburettor fully assembled. Testing should always NOTE! be carried out after the carburettor has been Cleanliness is very important when reas- repaired, but can also be performed for trouble- sembling the carburettor.
Repair instructions Connect the leads to the stop switch. Fit the carburettor. Screw in the carburettor bolts directly from behind, without lifting the carburettor assembly. Tighten to a torque of 1–1.5 Nm. It is important to hold the carburettor flange while tightening the bolts to prevent the inlet manifold from moving.
Repair instructions Air intake system – removal The air intake system comprises: • inlet manifold • insulating plate with clip • carburettor flange • impulse hose • support ring Remove: Unscrew the four cylinder bolts. Lift up the cylinder • cylinder cover so that the intake system insulating plate is free of •...
Repair instructions Air intake system – refitting Refit the carburettor. Screw in the carburettor bolts directly from behind without lifting the carburettor assembly, tightening to a torque of 1–1.5 Nm. It is important to hold the carburettor flange securely when tightening the bolts to prevent the inlet manifold from moving.
(less fuel in relation to the amount of air) Model Max revs Idle revs and turning them anti-clockwise makes the fuel/air 357XP/G 14 000 rpm 2 700 rpm mixture richer. A weak mixture increases the 359/G 13 500 rpm...
Repair instructions Fine adjustment of idling speed T Fuel tank – removal • The idling speed is adjusted using the screw WARNING! marked T. The fuel used in chainsaws is • If adjustment is necessary, screw in the idling harmful if inhaled, may cause screw T until the chain starts to turn.
Repair instructions Cleaning and inspection Carefully check that: • there are no leaks from the fuel tank • there are no leaks from the tank filler cap • the fuel hose is undamaged and free from wear • the fuel filter is not clogged •...
Repair instructions Tank vent – testing Fit the throttle pushrod in the tank and connect it to Connect pressure gauge 502 50 38-01 to the fuel the carburettor. Refit the spring. hose. Pump the pressure up to 50 kPa (0.5 bar). The pressure should drop to 20 kPa (0.2 bar) within 60 seconds.
Repair instructions Piston and cylinder – removal Remove: • cylinder cover • carburettor, see ”Carburettor - removal” • silencer • spark plug. Remove the circlips from the ends of the gudgeon pin and press it out. Then lift off the piston. Unbolt the vibration damping spring from the hand grip.
Repair instructions Cleaning and inspection Pump up the pressure to 80 kPa (0.8 bar). Clean all the components, scraping off all traces of old gasket and carbon from the following places: Wait 30 seconds. • Piston crown • Top of the cylinder bore •...
Repair instructions Fit the inlet manifold 503 86 63-01 to the cylinder. Check that the impulse tube is correctly seated in the impulse channel. NOTE! It is very important that there are no leaks in the inlet system, otherwise the engine Fit a new cylinder base gasket.
Repair instructions Crankshaft bearings – replacement If the crankshaft bearings are to be replaced they WARNING! must be pulled off the crankshaft using puller 504 Take care not to burn yourself 90 90-02. The new bearings must be shrunk-fit into when the crankcase is hot.
Repair instructions Crankcase and crankshaft – reassembly 357 only: Fit the cups on the crankshaft. NOTE! Place the flywheel side of the crankcase over the It is important that the cups are fitted over crankshaft and pull the two crankcase halves the counterweights.
Repair instructions Refit the following parts: Repairing damaged threads • bark rest, 8-10 Nm A repair kit, 503 27 33-01, is available for repairing damaged threads. • oil pump, 3-4 Nm, see ”Oil pump - refitting” • chain tensioner First drill out the hole using: 6.1 mm drill bit for magnesium crankcase •...
Appendix A Carburettor – EPA models 6. Adjust the H-needle to a top speed of "B" rpm. Model 357XP B= 14 500 Basic adjustment for EPA carburettors Model 359 B= 13 000 After replacing the carburettor or high speed and/or low speed needle on an EPA (The US Environmen- tal Protection Agency) certified product a basic 7.