Husqvarna 268K, 272K Workshop Manual Download Page 3 | Manualshive

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English –

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INTRODUCTION

As production continues, changes will be intro-
duced successively to the chain saw. If at any
time these changes influence service and/or
spares, special service announcements will be
sent out, which means that this manual will cease
to be current with time. In order to avoid prob-
lems, the manual should always be read together
with all service announcements that apply to the
specific model of chain saw.

Layout

The descriptive sections in this workshop manual
are set out in a number of flow diagrams. When
carrying out repairs on a specific chain saw,
follow the signs that apply to the saw in question.

Diagrams are not numbered as they are linked to
the actual text, either by lines or by being in the
same box.

Positional directives to components inside the
diagrams are designated with A, B, etc. and start
from A again in each new section.

General

Updates

Always use Husqvarna original:

•

Spare parts

•

Service tools

•

Accessories

For specific procedures special tools are re-
quired. In this workshop manual, all the service
tools required are listed. Use of the tools is
described in appropriate sections.

Tools

This workshop manual provides a detailed de-
scription of procedures for trouble shooting, repair
and testing of the chain saws. Safety precautions
that should be taken during repair are also
described.

This workshop manual applies to the engine
assembly in the following chain saws:

36
40

41
42

45
51
55
61

242XP
246
254XP

257
262XP
268

272XP
268K
272K
272S

281XP
288XP

394XP
3120XP

Safety

Note!
The section dealing with safety should be
read and understood by all who carry out
repair or service work on the chain saw.

Target group

There are warning symbols on the chain saw. If a
warning symbol has been damaged or is missing,
it must be replaced immediately in order to
maximise safety when the saw is in use.

This workshop manual is written for personnel
that are assumed to have general knowledge of
service and repair of small engines.

The workshop manual should be read and under-
stood by all personnel carrying out service and
repair work on the chain saw. The manual is also
suitable for use in the training of new employees.

Eng, p 2-39

96-09-13, 09.05

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Summary of Contents for 268K, 272K

Page 1: ...101 88 55 26 Workshop Manual Husqvarna Chain Saws ...

Page 2: ...cal Data 6 Tools 14 Service data 20 Trouble shooting 40 Safety equipment 42 Starter 57 Electrical system 61 Centrifugal clutch 67 Lubrication system 70 Carburettor 83 Air filter 101 Tank unit 103 Anti vibration system 106 Piston cylinder 108 Crankcase and crankshaft 114 ...

Page 3: ...al tools are re quired In this workshop manual all the service tools required are listed Use of the tools is described in appropriate sections Tools This workshop manual provides a detailed de scription of procedures for trouble shooting repair and testing of the chain saws Safety precautions that should be taken during repair are also described This workshop manual applies to the engine assembly ...

Page 4: ...case and carry out the instruc tions under Assembly Refer to pages 111 112 which deals with the Piston and Cylinder and carry out the instructions under Assembly Refer to pages 107 which deals with the Anti vibration system and carry out the instructions under Assembly Refer to page 105 which deals with the Tank unit and carry out the instructions under Assembly Continue to work backwards through ...

Page 5: ...After testing do not touch the silencer until it has cooled Risk of burns This especially applies if the saw is fitted with a catalytic converter The coating on and in the catalytic element is hazardous to touch Use protective gloves when working on the catalytic converter Inadequate chain lubrication can result in the chain breaking which can cause serious or fatal injury Make sure that the start...

Page 6: ...C1Q EL1 41 0 5 02 PHELON 0 3 012 WALBRO WT 239 42 0 5 02 SEM AM 7 0 3 012 WALBRO HDA 98 45 0 5 02 PHELON 0 3 012 ZAMA C1Q EL1 51 0 5 02 ELECTROLUX ET 0 3 012 WALBRO WT 170 36 33 46 13 18 17 3 9000 rpm 325 3 8 1 3 050 40 33 46 13 18 17 4 8500 rpm 325 1 3 050 41 33 46 13 18 17 3 9000 rpm 325 3 8 1 3 050 42 28 46 11 18 17 9 9300 rpm 325 1 5 058 1 3 0501 45 33 46 13 18 17 4 8500 rpm 325 1 3 050 51 33 ...

Page 7: ...7 Y 42 2700 3800 14500 RCJ 7 Y 45 2500 3600 12500 RCJ 7 Y 51 2500 3700 12500 RCJ 7 Y 36 0 4 7 0 2 Yes 40 0 5 8 0 25 Yes 41 0 4 7 0 2 Yes 42 0 5 3 7 0 27 Yes 45 0 5 8 0 25 Yes 51 0 6 10 0 3 Yes 36 4 6 5 3 13 No 40 4 7 5 4 13 No 41 4 6 5 3 13 No 42 4 7 5 5 13 No 45 4 7 5 4 13 No 51 5 2 6 2 15 No Weight without bar and chain Weight with bar and chain Handle heater kg kg lbs Watt r min Idling speed En...

Page 8: ...LECTROLUX ET 0 3 012 WALBRO WT 170 61 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 254 242XP 0 5 02 SEM AM 7 0 3 012 WALBRO HDA 98 246 0 5 02 SEM AM 7 0 3 012 WALBRO HDA 98 254XP 0 5 02 ELECTROLUX ET 0 3 012 WALBRO HDA 35B 257 0 5 02 ELECTROLUX ET 0 3 012 WALBRO HDA 120 55 38 51 15 20 17 4 9000 rpm 325 3 8 1 5 058 1 3 050 1 61 38 51 15 20 18 4 8300 rpm 3 8 1 5 058 242XP 28 46 11 18 19 1 9900 rpm 325 ...

Page 9: ... kg lbs Watt r min TECHNICAL DATA 55 2500 3700 12500 RCJ 7 Y 61 2500 3700 12000 RCJ 7 Y 242XP 2700 3900 15500 RCJ 7 Y 246 2700 3900 15000 RCJ 7 Y 254XP 2700 3700 13800 RCJ 7 Y 257 2700 3700 13500 RCJ 7 Y 55 0 6 10 0 3 Yes 61 0 75 4 8 12 17 0 45 Yes 242XP 0 5 3 7 0 27 Yes 246 0 5 3 7 0 27 Yes 254XP 0 6 3 10 0 3 Yes 257 0 6 3 10 0 3 Yes 55 5 2 6 2 15 No 61 6 1 7 1 15 No 242XP 4 7 5 5 13 65 10 000 24...

Page 10: ...50 0 34 0 9000 272K 72 52 0 34 0 9300 272S 72 52 0 34 0 9300 262XP 0 5 02 ELECTROLUX ET 0 3 012 WALBRO HDA 120 268 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 260 272XP 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 260 268K 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 255 272K 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 255 272S 0 5 02 ELECTROLUX ET 0 3 012 TILLOTSON HS 255 262XP 33 51 13 20 18 5 9600 rpm 32...

Page 11: ...hampion kg kg lbs Watt r min TECHNICAL DATA 262XP 2700 3400 13500 RCJ 7 Y 268 2500 3500 12500 RCJ 7 Y 272XP 2500 3500 13500 RCJ 7 Y 268K 2500 3500 10000 RCJ 7 Y 272K 2500 3500 10000 RCJ 7 Y 272S 2500 3500 10000 RCJ 7 Y 262XP 0 6 6 5 13 5 0 3 Yes 268 0 75 4 9 13 17 0 45 Yes 272XP 0 75 5 9 14 19 0 45 Yes 268K 0 75 272K 0 75 272S 0 75 262XP 5 8 6 8 13 65 10000 268 6 2 7 2 15 65 10000 272XP 6 3 7 3 15...

Page 12: ...0 9000 288XP 87 54 0 38 0 9300 394XP 94 56 0 38 0 8800 3120XP 119 60 0 42 0 9000 281XP 0 5 02 SEM AM 7 0 3 012 TILLOTSON HS 228 288XP 0 5 02 SEM AM 7 0 3 012 TILLOTSON HS 228 394XP 0 5 02 SEM AM 44 0 3 012 WALBRO WJ 39 3120XP 0 5 02 SEM AM 37 0 3 012 WALBRO WG 6 281XP 38 71 15 28 20 0 9000 rpm 3 8 1 5 058 288XP 38 71 15 28 20 7 9300 rpm 3 8 1 5 058 394XP 46 91 18 36 19 6 8800 rpm 3 8 404 1 5 058 1...

Page 13: ...t 8 500 rpm Litres r min r min r min Champion kg kg lbs Watt r min TECHNICAL DATA 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 281XP 0 9 9 12 15 18 0 5 Yes 288XP 0 9 9 12 15 18 0 5 Yes 394XP 0 9 14 21 0 5 Yes 3120XP 1 25 8 51 0 7 Yes 281XP 7 5 8 7 18 56 7200 288XP 7 5 8 7 18 56 7200 394XP 7 9 9 2 18 65 10000 3120XP 1...

Page 14: ...mm 502 50 22 01 8 mm 502 50 23 01 10 mm 502 71 13 01 502 51 34 02 0 3 mm 502 50 83 01 502 51 02 01 502 71 14 01 compl 502 50 70 01 502 50 37 01 502 70 09 01 502 50 88 01 5 mm 502 50 87 01 4 mm 502 50 86 01 3 mm 502 50 06 01 504 98 26 01 36 41 40 45 Tools for all chain saws TOOLS 502 51 91 01 0 5 mm ...

Page 15: ...90 90 01 502 51 61 01 51 55 502 50 30 09 502 50 79 01 55 40 910 1116 45 925 1168 504 90 29 02 502 54 03 01 40 45 55 502 50 46 01 55 compl 502 50 38 01 502 50 33 01 502 51 94 01 530 03 11 36 530 03 11 12 502 51 00 02 Tools for saws 36 and 41 Tools for saws 40 45 51 and 55 TOOLS 502 50 99 01 55 502 50 26 01 55 505 38 18 17 40 45 ...

Page 16: ...45 01 502 50 46 01 compl 502 50 38 01 compl 502 51 49 02 3 mm 4 mm 8 mm 502 50 33 01 502 50 72 01 502 50 71 01 502 50 45 01 502 50 46 01 compl 502 50 38 01 504 90 90 01 502 51 61 01 502 50 79 01 502 50 30 10 Tools for saws 42 242 and 246 Tools for saws 254 257 and 262 TOOLS compl 502 51 49 02 502 51 49 01 502 51 54 01 502 50 26 01 502 50 99 01 502 51 49 01 502 51 54 01 502 50 99 01 502 50 26 01 ...

Page 17: ...02 71 36 01 4 mm 502 50 33 01 502 50 82 01 502 50 66 02 502 50 47 01 502 50 81 01 compl 502 50 38 01 502 51 61 01 504 90 90 01 502 50 53 01 502 50 52 01 502 50 30 04 502 50 30 08 502 51 69 01 268 502 50 66 02 502 50 67 01 502 51 00 02 502 50 46 01 TOOLS Tools for saws 61 268 and 272 Tools for saws 281 and 288 502 50 26 01 502 51 49 01 502 51 54 01 502 50 26 01 502 51 49 01 502 51 54 01 compl 502 5...

Page 18: ... 50 82 01 502 50 66 02 502 52 01 01 394 502 71 38 01 3120 compl 502 50 38 01 504 90 90 01 502 50 52 01 502 50 30 08 502 52 04 01 394 502 71 40 01 3120 502 71 39 01 394 TOOLS Tools for saws 394 and 3120 compl 502 51 49 02 502 51 49 01 502 51 54 01 502 50 26 01 ...

Page 19: ...02 50 79 01 Assembly mandrel 502 50 81 01 Cover plate 502 50 82 01 Assembly mandrel 502 50 83 01 Hook tank valve 502 50 86 01 Allen key 502 50 87 01 Allen key 502 50 88 01 Allen key 502 50 99 01 Puller sleeve 502 51 00 02 U key 502 51 02 01 Assembly fixture 502 51 32 01 Assembly sleeve 502 51 34 02 Feeler gauge 502 51 49 01 Puller 502 51 49 02 Puller 502 51 50 01 Socket 502 51 54 01 Bolt set 502 5...

Page 20: ... 41 SERVICE DATA 5 10 15 4 6 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: ...English 21 SERVICE DATA 15 4 6 4 3 28 4 ...

Page 22: ...5 15 4 8 3 242 42 246 10 5 42 246 242 7 8 8 10 4 5 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: ...English 23 SERVICE DATA 20 4 2 4 28 2 9 3 2 9 6 2 2 13 ...

Page 24: ...DATA 3 4 2 3 25 35 7 8 2 3 2 3 2 3 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 ...

Page 25: ...English 25 SERVICE DATA 3 4 2 3 2 3 25 30 2 3 2 3 2 3 2 3 8 10 2 3 2 3 3 4 20 2 3 ...

Page 26: ... 4 5 15 6 8 7 8 30 40 3 4 3 4 8 10 3 4 1 5 2 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: ...English 27 SERVICE DATA 15 25 12 14 8 10 3 4 3 4 3 4 3 5 3 4 3 4 1 2 ...

Page 28: ... SERVICE DATA 5 8 15 4 5 10 10 5 35 3 5 3 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: ...English 29 254 SERVICE DATA 5 3 2 28 4 10 20 4 13 4 9 3 5 ...

Page 30: ...E DATA 5 8 15 4 6 10 35 4 4 3 4 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 31: ...English 31 SERVICE DATA 2 2 28 4 9 20 4 5 13 4 4 5 3 9 5 ...

Page 32: ... SERVICE DATA 5 8 15 6 10 5 10 2 35 6 6 35 1 4 3 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: ...English 33 272 268 272 61 SERVICE DATA 3 4 28 4 10 15 4 3 3 5 14 6 4 6 1 1 3 1 3 9 3 ...

Page 34: ... SERVICE DATA 5 8 15 6 13 5 4 35 6 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: ...English 35 SERVICE DATA 6 4 35 11 20 7 7 3 17 3 4 7 7 6 4 3 1 9 ...

Page 36: ...2 4 10 12 6 8 7 9 SERVICE DATA Character key Numbers by components that are bolted refer to the tightening torque in Nm Locking fluid Loctite Lubricate using two stroke oil Lubricate using saw chain oil Lubricate using grease ...

Page 37: ...English 37 SERVICE DATA 30 40 10 12 5 6 6 2 3 4 5 3 5 3 5 5 6 20 22 5 12 14 ...

Page 38: ...ATA 5 8 15 5 12 5 38 7 8 5 7 5 1 3 4 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 39: ...English 39 SERVICE DATA 5 4 40 12 20 4 12 17 10 8 9 4 6 5 5 7 3 3 ...

Page 40: ...diaphragm Worn needle valve needle Control system sticking Control system set too high Leak in control system air or fuel Loose cover on carburettor pump side Worn needle valve Control system set too high Control system sticking Difficult starting Carburettor leaking fuel Flooding when the engine is not running Faults that can develop on the chain saw are divided into four groups as follows In eac...

Page 41: ...bled Loose diaphragm Hole in diaphragm Leaking control diaphragm cover Will not run at full throttle Low power Will not four stroke High rpm Acceleration and retardation Does not accelerate Motor stalls when throttle released Over rich accelera tion Adjust L screw Adjust H screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse ch...

Page 42: ...mantling 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 Dismantle the other part of the bushing by means of a punch Remove the cylindrical pin A Slide the hand guard forwards so that the brake is actuated Dismantle the clutch cover and clean See the operating instructions Removethecoveronthechainbrakespring The...

Page 43: ...e clutch cover Dismantle the pressure rod from the brake band All saws except 3120 Remove the screw that holds the fixed end of the band 40 42 45 51 242 246 55 254 257 262 and 394 36 41 61 268 272 281 and 288 Knock out the band s fixed end using a punch through the hole in the clutch cover and remove the loose parts Lift up the band s fixed end using a screw driver and remove the loose parts SAFET...

Page 44: ...nder 0 8 mm at any point Assembly Fit the band s fixed end into position on the clutch cover All saws except 3120 3120 Continues on next page 3120 continues on next page Fit the screw that holds the band s fixed end Greasethekneelinkandknockinthetubular pin that holds the knee link SAFETY EQUIPMENT Min 0 8 mm ...

Page 45: ...essure rod on the brake band Note Plastic sleeve Bottom the screw onto the pressure rod thread and back off 4 5 turns Grease and fit the ratchet Set the unit in a vice positioned in the jaws as shown below WARNING If the clutch cover slides out of the vice s grip the spring can fly out with immense force resulting in personal injury 3120 continues on next page Continues on next page SAFETY EQUIPME...

Page 46: ...for the tubular pin and the ratchet align Carefully knock in the pin Fit the hand guard the two bushings and the screw Fit the cylindrical pin Pull back the hand guard so that the brake is not actuated SAFETY EQUIPMENT Check the chain brake as described on the next page 3120 ...

Page 47: ... WARNING After repair the chain brake must be checked as set out in the following instructions Checking brake operation Hold the chain saw above a firm surface The distance between the bar and the surface are shown in the table below SAFETY EQUIPMENT Release the front handle and let the chain saw rotate around the rear handle When the bar nose hits the surface the chain brake should trip ...

Page 48: ...sed Aluminium angle Plastic angle Fixed roller Rotating roller The following securing methods are used Using screws on the crankcase Using screws on the spike Using nuts on the spike Replacing Dismantle the chain and bar See the oper ating instructions Reassemble the chain and bar See the operating instructions Check the chain catcher and replace if bro ken or badly damaged The tightening torque i...

Page 49: ...6 bolts M5 or M6 nuts Removethemuffler gasketandcoolingplate B if the saw is so equipped If the saw is equipped with a spark arrester C remove this Saws 36 and 41 Saw 242 Cat Dismantle the muffler as shown in the figure to the right Dismantle the muffler as shown in the figure to the right A 1 WARNING The coating on and in the catalytic converter element A is hazardous to your health if touched We...

Page 50: ...tening torques 1 Secure the muffler on the cylinder using the two bolts D 2 Assemble the muffler components using the four bolts E 3 Secure the muffler to the crankcase using the two bolts F and Loctite Only specially treated bolts may be used on the catalytic converter high temperature See spare parts catalogue 1 Tighten all bolts using the tightening torque set out in the Service data WARNING Th...

Page 51: ...lean 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 In the run position morethan1000ohm Assembly Fit the earth screw A and cable B Note Onsomemodelstheearthcableshould be connected to the earth screw SAFETY EQUIPMENT B C A Press the switch into the socket on the tank unit ...

Page 52: ...SAFETY EQUIPMENT Turn the throttle lock as shown in the figure and lift it out with the spring from the cut out in the handle Saw 394 Slide the throttle lock and remove it forwards as shown in the figure Saws61 268 268K 272XP 272K 272S 281XP 288XP and 394 Saws61 268 272XP 272K 272S 281XP and 288XP Continues on next page Carefully prise up the lock from the slot and remove Saws 36 41 42 55 242XP 24...

Page 53: ...emove the three pins with a punch Press the throttle lock down and move it and the trigger forwards until the back edge of the lock appears Lift out the trigger lock Remove the springs where appropriate Saws36 41 42 55 242XP 246 51 254XP 257 and 262XP Remove the rubber element A Slide out the throttle pin B and lift out the throttle arm and spring A B A SAFETY EQUIPMENT Saws61 268 268K 272XP 272K ...

Page 54: ...s where fitted are OK and have the correct tension Check that the lock s activation mechanism is not worn For examples of the activation mechanism see the figure SAFETY EQUIPMENT On those saws fitted with a throttle cable check that the cable and lever are OK and run freely ...

Page 55: ...Fit the side of the handle using three screws on the side and one underneath which holds the spring Fit the spring and slide the throttle lock forwards from above so that its rear edge canbeslidinundertheedge of the handle All saws except 40 and 45 continue on the next page Saws 61 268 268K 272XP 272K 272S 281XP and 288XP See next page Saws36 41 42 242XP 246 51 55 254XP 257 262XP and 394 B WARNING...

Page 56: ...P 272K 272S 281XP and 288XP Fit the throttle lock and spring On saw 394 twist as shown in the figure when fitting Fit the throttle arm and spring Fit the pin and the two rubber dampers Saws36 41 42 242XP 246 51 55 254XP 257 262XP and 394 Fit the throttle lock from the front Fit the throttle lock pin Fit the tank unit See page 105 ...

Page 57: ...rd guide A remove this Lift out the starter pulley carefully If the cord is to be replaced cut it off and pull outthebitsfromthehandleandstarterpulley using a pair of long nosed pliers WARNING Ensure that the spring does not flyoutandcausepersonalinjury Wear protective glasses If the spring is to be replaced remove the old spring from the starter pulley Some saws have a protective plate over the s...

Page 58: ...owing The starter cord The dogs in the starter pulley That the pawls on the flywheel are OK and springbacktowardsthecentreandmovefreely STARTER Changing the ferrule Remove the parts of the old ferrule Fit the new ferrule in the starter housing Use a wrench spacer A and ball B Splay out the ferrule on the inside as shown in the figure B A ...

Page 59: ...lide in the spring and remove the security holder 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 36 and 41 Screw the cord to the starter pulley Secure the cord on the starter pulley Knot the cord on the starter pulley 61 268 272 281 and 288 42 242 246 51 55 254 257 262 394 and 3120 Continues on next pa...

Page 60: ...he handle secure with a double knot Pull out the cord 20 30 cm and insert it into the cut out on the starter pulley rim Some saws have several long cut outs Rotate the starter pulley clockwise until the cord is correctly tensioned A Pull out the cord completely and hold the pulley with your thumb B In this position it should be possible to turn the starter pulley a further 1 2 3 4 turn Fit the sta...

Page 61: ...Release the cables from the guide rail and remove the guide rail In the event of a fault in the ignition system the ignition module should be checked before dismantling the ignition system Check the ignition module as follows Connect test spark plug 502 71 13 01 to the HT lead and clamp the test spark plug to the cylinder Turn the engine over using the starter If the test spark plug sparks the ign...

Page 62: ...e shaft All saws except 36 and 41 Fit puller 502 51 49 02 and loosen the flywheel Remove the puller nut and flywheel Continuation all saws Remove the ignition coil ELECTRICAL SYSTEM The generator can be unscrewed if the saw is fitted with a handle heating system Remove all parts so that the cable can be released See applicable sections ...

Page 63: ...her and nut Tightening torque see Service data Remove the piston stop Fit the ignition module without tightening the screws Turn the flywheel so that its magnet is beside the ignition module ELECTRICAL SYSTEM Clean all parts especially the flywheel and shaft taper Check that the flywheel is not cracked or damaged in any other way Place the flywheel on the crankshaft Rotate gently until the flywhee...

Page 64: ...he stop switch is described in the section Safety equipment See page 51 Saws 42 242 246 281 and 288 Other saws Push the HT cable through the spark plug cover and fit the contact spring using the pliers Slide the spark plug cover over the contact spring Fit the ignition coil which is located next to the carburettor and connect the cables Fit the starter and cylinder cover Fit the starter and cylind...

Page 65: ...ts can vary from saw to saw A1 B C D E A2 Trouble shooting can take place with most components connected to the saw An ohm meter is required for trouble shooting Before trouble shooting individual components remove the power switch and disconnect one of the switch s cables Remove other components as necessary E g the cylinder cover See the operating instructions Troubleshootingindividualcomponents...

Page 66: ...ohm Replace the handle loop that has a higher value Connect the ohm meter to points C and D The ohm meter should read 0 7 2 5 ohm Replace a heat loops that has higher values Check the handle loop Checking the heat loops in the rear handles A1 B B C Connect the ohm meter across the switch The ohm meter should read more than 1000 ohm with the switch in position 0 The ohm meter should read at the hig...

Page 67: ...12 Note Left hand thread Saws with three coil springs Remove the spring by first lifting a shoe using a suitable spacer A Then remove the clutch shoes Remove the springs using a screwdriver Then remove the clutch shoes Saws with one long spring Prise out the spring heels usingascrewdriver Remove the springs from the other side using circlip pliers Then remove the clutch shoes CENTRIFUGAL CLUTCH A ...

Page 68: ... for wear on the chain sprocket Check the condition of the needle bearing and the bearing surface on the crankshaft That the clutch drum friction surface and bearing surface are undamaged That measurement B is not under 1 mm Clean all parts and inspect the following CENTRIFUGAL CLUTCH B A Clutch shoes with chamfers Clutch shoes withoutchamfers ...

Page 69: ...secure the clutch centre On saws 36 and 41 use service tool no 530 03 11 12 Note Left hand thread Saws with three coil springs Saws with one long spring Saws with three C springs Locate the clutch shoes on the hub and fit the springs with the help of pliers Locate the clutch shoes on the hub Lift a shoe using a suit able spacer A and fit the spring Locate the clutch shoes on the hub and fit the sp...

Page 70: ... washer Other pumps have a cut out C for a screwdriver to prise off the pump Both types are shown below Saws 42 242XP 246 254XP 262XP and 257 Saws 61 268 272XP See next page Saws 281XP and 288 XP See next page Saw 394 See page 72 Dismantle the oil pump as follows 1 Unscrew screw A and remove locking clip B 2 Undo screw C 3 Lever out the pump piston D and plastic plug E using a screwdriver 4 Remove...

Page 71: ...at the pump piston D slides out of the housing 4 Remove the pinion E with washers and springs 5 Remove the pin F 6 Remove the seal G 7 If necessary remove the O ring H A H F B G E C D F A D E C B Saws 281XP and 288 XP Dismantle the oil pump as follows 1 Undo the adjuster screw A 2 Remove the plug B with pump piston C and spring with washers 3 Dismantle the O ring D Replace if necessary 4 If necess...

Page 72: ...sing a screwdriver 3 Remove the seal E A B C D E Saw 3120 Undo the three bolts that hold the oil pump and lift up the pump by the cut out for the adjuster screw Lift off the pump and loosen the wire for manual oil supply Dismantle the oil pump as follows 1 Undo the screws A and remove the parts as shown in the figure below 2 Undo screw B NOTE Left hand thread B A LUBRICATION SYSTEM ...

Page 73: ...s shown in respective diagrams below 36 41 40 45 51 55 Saws 36 40 41 and 45 Undo the two bolts and lift off the pump and the upper seal LUBRICATION SYSTEM Saws 51 and 55 Lift off the pump and the upper seal Take the pump apart as shown in the exploded view on the next page ...

Page 74: ...74 English LUBRICATION SYSTEM 36 41 40 45 50 51 A Lower seal B Pump cylinder C Upper seal D Chain guide plate E Pump housing F Pump piston G Worm gear C B A D E F G D E F G C B A A B C E F G ...

Page 75: ... 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: ... 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 The oil pipe is not blocked and the filter screen is clean That all seals are undamaged That the worm gear on the oil pump drive is undamaged That the pump piston s pinion gear is undamaged ...

Page 77: ...ntinuation page 80 Assembling the worm gear On those saws where the oil pump worm gear is pressed on the crankshaft Screw the worm gear into the dismantling tool and press the worm gear onto the crankshaft until it bottoms against the collar Fit the oil pump as follows 1 Apply SAE 30 oil to all moving parts 2 Fit the seal G if necessary 3 Press in pin F 4 Locate the pinion E with washers and sprin...

Page 78: ...e pump housing 4 Fit the adjuster screw A in the pump housing and through the hole in plug B 5 Fit the O rings D and F Saw 394 Fit the oil pump as follows 1 Apply SAE 30 oil to all moving parts 2 Fit the pump piston C with washers and spring in the pump housing 3 Fit the latch pin B press in the pump piston C a little more and fit the adjuster screw A 4 Fit the seal E 5 Fit the plug D A B C D E Se...

Page 79: ...osition with a screwdriver from the pump housing s inside in slot E 4 Fit screw B so that it is positioned approx one turn from the bottom NOTE Left hand thread B A 5 Fit lever arm F 6 Fit units B F G with spring H and screw in position using screws A and latch J 7 Remove the screwdriver 8 Fit a new O rings K and L C K F D E H G J Fit the wire for manual oil supply See continuation on next page ...

Page 80: ...by tightening the three bolts 3 If the tapered sleeve has been used remove it 4 Fit the centrifugal clutch See page 69 5 Fit the bar and chain 6 Adjust the oil pump for the correct oil flow See the operating instructions 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: ... gear C B A D E F G D E F G C B A A B C E F G LUBRICATION SYSTEM Fit the oil pump as follows 1 Apply SAE 30 oil to all moving parts 2 Fit the worm gear G on the crankshaft if necessary 3 Fit the pump piston F in the pump cylinder B 4 Fill the pump recess with grease 5 Fit the unit in the pump housing E Ensure the pump cylinder s cut out aligns in the pump housing 6 Fit the lower seal A on the cran...

Page 82: ...spective diagrams below 36 41 40 45 51 55 Fit the oil pump in the crankcase tighten the two bolts and fit the upper seal Fit the oil pump in the crankcase and fit the upper seal LUBRICATION SYSTEM Saws 36 40 41 and 45 Saws 51 and 55 Fit the bar and chain ...

Page 83: ...ve and diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark The carburettor consists of three sub systems Metering unit A Mixing venturi B Pump unit C In the pump unit C fuel is pumped from the fuel tank to the metering unit One side of the pump diaphragm is connected to the crankcase and pulses in time with the pressure changes in the ...

Page 84: ...fuel is supplied through the diffuser jet G In the part throttle mode the throttle valve H is partially open Fuel is supplied through the diffuser jets F and G In the full throttle mode both valves are open and fuel is supplied through all three diffuser jets E F and G CARBURETTOR In the cold start mode the choke valve D is fully closed This increases the vacuum in the carburettor and fuel is easi...

Page 85: ...f the fuel passes through the jet Below or next to the jet is a screen which needs to be cleaned Dismantle the jet and or screen in one of the following ways 1 Knock the unit into the venturi using a punch and take the unit apart some Tillotson models 2 Dismantle the lock washer over the jet and lift off the jet and screen Dismantle all parts necessary and remove the carburettor from the saw On so...

Page 86: ...e valves as well as the shafts lever arms and springs 8 Remove the speed governor I Only 272K 268K and 272S 9 Remove the semi fixed jet K See page 85 A B H E F G J C D D CARBURETTOR 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 Remove the cover E over the ...

Page 87: ...e the throttle and choke valves as well as the shafts lever arms and springs Tillotson HS 260 A A B H E F G J C H K 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 Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm...

Page 88: ...s as well as the shafts lever arms and springs 8 Remove the semi fixed jet K See page 85 Walbro WJ A B H E F G J C K 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 Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphrag...

Page 89: ...le and choke valves as well as the shafts lever arms and springs 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 Remove the cover E over the pump unit and carefully remove the gasket F and the pump diaphragm G 4 Using a needle or the like carefully remove th...

Page 90: ... shafts 3 That the needle valve and its lever are not worn 4 That the fuel screen is undamaged 5 That the tips of the high and low speed jet screws are not damaged 6 On Tillotson HS 255 B that the speed governor I is clean 7 That the air intake manifold is not cracked WARNING The fuel used in the chain saw poses the following hazards 1 The liquid and its vapours are poisonous 2 Can cause skin irri...

Page 91: ...jet Below or next to the jet is a screen which needs to be cleaned Reassemble the jet and or screen in one of the following ways 1 Put together the unit and fit it in the carburettor by means of a punch Some Tillotson models 2 Fit the jet with screen and lock washer CARBURETTOR Assembly Refer to the carburettor in question on the next eight pages A pressure test see page 100 should be carried out ...

Page 92: ... 5 Fit the pump diaphragm G gasket F and cover E on the pump unit 6 Fit the needle valve C with lever arm shaft and spring and tighten screw H 7 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 8 Fit the control diaphragm B with gasket and cover A on the met...

Page 93: ...gasket F and cover E on the pump unit 7 Fit the needle valve C with lever arm shaft and spring and tighten screw H 8 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 9 Fit the speed governor I Lock with Loctite or locking lacquer Only applies to 272K 268K an...

Page 94: ...e of a small screwdriver 6 Fit the pump diaphragm G gasket F and cover E on the pump unit 7 Fit the needle valve C with lever arm shaft and spring and tighten screw H 8 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 9 Fit the control diaphragm B with gaske...

Page 95: ...ump diaphragm G gasket F and cover E on the pump unit 6 Fit the needle valve C with lever arm shaft and spring and tighten screw H 7 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 8 Fit the control diaphragm B with gasket and cover A on the metering unit 9...

Page 96: ...crewdriver 6 Fit the pump diaphragm G gasket F and cover E on the pump unit 7 Fit the needle valve C with lever arm shaft and spring and tighten screw H 8 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 9 Fit the control diaphragm B with gasket and cover A ...

Page 97: ...et screws and springs NOTE Do not tighten the screws against the seats This can damage the seats and needle tips 5 Fit the fuel screen D by using the handle of a small screwdriver 6 Fit the pump diaphragm G gasket F and cover E on the pump unit 7 Fit the needle valve C with lever arm shaft and spring and tighten screw H 8 Check using or a ruler or the like that the lever arm is level with the cham...

Page 98: ... a small screwdriver 6 Fit the pump diaphragm G gasket F and cover E on the pump unit 7 Fit the needle valve C with lever arm shaft and spring and tighten screw H 8 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 9 Fit the control diaphragm B with gasket an...

Page 99: ...pump diaphragm G gasket F and cover E on the pump unit 5 Fit the needle valve C with lever arm shaft and spring and tighten screw H 6 Check using or a ruler or the like that the lever arm is level with the chamber floor See the figure to the lower right The lever arm can be bent if necessary to achieve the correct settings 7 Fit the control diaphragm B with gasket and cover A on the metering unit ...

Page 100: ...ter 4 Pump up the pressure to 50 kPa 0 5 bar and clamp the pump tube with the spring clip 5 There should be no leakage If a leakage occurs refer to the table below Pressure testing should be carried out with the carburettor fully assembled Testing should always be carried out after the carburettor has been repaired but a test can also be made for trouble shooting before dismantling WARNING The fue...

Page 101: ... filter which is easily accessible under the filter cover A In dusty conditions this filter should be checked replaced after every second refuelling The filter should be cleaned and oiled regu larly to obtain maximum filtration efficiency Cleaning Dismantle the filter Wash the filter in warm soapy water After cleaning rinse the filter thoroughly in clean water Squeeze and let the filter dry NOTE C...

Page 102: ...per 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 Note The filter must not be washed B ...

Page 103: ... Dismantle the bolts as shown in the figures and the table on the next page and lift off the tank unit from the engine sub assembly If heated handles are fitted remove the con nections The cable to the switch cannot be removed before the tank unit and the engine sub assembly are separated NOTE Take care that the fuel pipe and throttle cable are not damaged Cleaning and Inspection Clean all parts a...

Page 104: ...K Has no tank unit A D F K A D under a cover F G L Has no tank unit A D F L all under covers A D F L all under covers A C D F G K A D under a cover F G L A D under a cover F G L A D F L A D F L A D F L A C D F G K A C D F G K A C D F G K A C D F G K A C D F G K A C D F G K A C D F G K B E G I H C D F I J Saw Bolts placed at A B C D E F G H I K J L ...

Page 105: ...to the tank unit and at the same time insert the fuel pipe in the bottom of the carburettor space If the saw has a throttle cable insert this into the carburettor space too NOTE Ensure that the fuel pipe and throttle cable are not damaged Fit the bolts as set out in the table on the previous page Tightening torques see the service data for the saw in question The figures on the previous page illus...

Page 106: ...s The system s movement limitation consists of side absorbers and or stop screws Remove the rubber element using re spective tools as shown in the figure below Saws 40 45 and 3120 Saw 394 Other saws The tank unit must be removed from the engine sub assembly to access the anti vibration system See the previous pages Release the catch on the plastic key Remove the spring element using an allen key a...

Page 107: ...n in the figure below Saw 394 Other saws Slide in the spring and its holder Fit the spring element using an allen key as shown in the figure below Fit the rubber stop with the help of a wire or the like Saws 40 45 and 3120 Fitting the anti vibration system s damper element Tightening torques see the Service data for respective saws ...

Page 108: ...case Remove the ignition coil On saw 394 disconnect the anti vibration spring A from the cylinder On all chain saws undo the four cylinder bolts B The bolts are removed using a 4 mm allen key smaller saws or 3 16 allen key larger saws Immediately cover the crankcase opening crankshaft and crankshaft bearing with a paper or cloth Remove one of the circlips on the piston push out the gudgeon pin and...

Page 109: ...the piston is free of score marks See Faults and causes on the next page Small scratches can be polished off using fine emery paper 4 That the piston ring is not stuck into its groove 5 Measure the piston ring wear by placing it in the bottom of the cylinder bore and measuring the gap and which should not exceed 1 mm 6 That the needle bearing is undamaged 7 That the intake manifold is undamaged Ma...

Page 110: ...or incorrect oil in the fuel PISTON AND CYLINDER Piston ring breakage 1 Excessive engine speed 2 Piston ring worn out 3 Oversized piston ring groove Carbon build up 1 Incorrect carburettor setting max speed too low 2 Too much or incorrect oil in the fuel Onsaws40and45 checktherubbersealing on the shaft seat Change the shaft seat if necessary ...

Page 111: ...articles fall into the crankcase Applysiliconerubber50498 26 01 to the lower crank casehalf scontactsurfaces Check that the seals fit in their grooves correctly Tighten the crankcase halves Tightening torque refer to Service data Oil the piston and piston ring Compress the piston ring either by hand or by using tool 502 50 70 01 Carefully fit the cylinder Other saws Seecontinuationonnextpage Saws ...

Page 112: ...wall between the cylinder and carburettor Fit the following parts Cylinder cover See operating instructions Spark plug See operating instructions Carburettor Muffler Carry out a pressure test as set out on the next page If a new piston or cylinder has been fitted the saw must be run in for 3 4 hours with the carburettor set to the basic settings See the operating instructions for the saw in questi...

Page 113: ...n valve should be closed 3 Plug the opening to the impulse channel 4 Pump up the pressure to 80 kPa 0 8 bar 5 Wait 30 seconds 6 The pressure should not drop below 60 kPa 0 6 bar 7 Leakage can occur from the decompression valve and the crankshaft seals Fit the following Decompression valve Crankcase and cylinder Test the decompression valve as follows 1 Connect the tool 502 50 38 01 to the decompre...

Page 114: ...ocation of the bolts that are of a different length Split the crankcase using tool 502 51 61 01 D Centrifugal clutch See page 67 E Oil pump See page 70 F Carburettor G Muffler See page 49 H Piston and cylinder See page 108 I Tank unit See page 103 Saw 394 Other saws Other saws Saws36 40 41and45 Seenextpage See continuation on next page A B This section deals with the following Crankcase and cranks...

Page 115: ...g puller 502 90 90 01 Split the shaft support and dismantle the halves If the crankshaft bearing still remains on the crankshaft when dismantling remove it using puller 502 90 90 01 CRANKCASE AND CRANKSHAFT Saws 36 and 41 Saws 40 and 45 Remove all rubber and plastic components from the crankcase halves Heat the crankcase half in question to 200 C Wear protective gloves and knock the crankcase half...

Page 116: ...ng does not have any radial play Axial play is acceptable That the big end bearing does not have any score marks or discoloration on the sides That the little end bearing surfaces are not scored or discoloured That the crankshaft bearings do not show signs of play have an abnormal noise level and rotate smoothly That the sealing surfaces on the crankcase seals are not worn and that the rubber has ...

Page 117: ...e half cool before continuing work Fit the bearing and seals on the crankshaft Grease the seals Continue assembly as described on page 111 Saws 36 and 41 Saws 40 and 45 See page 120 WARNING Thecrankcasehalvescanbehot Risk of burns Wear protective gloves If new seals need to be fitted in the crankcase grease the sealing surfaces and knock in the seals using respective punchs see Service tools The s...

Page 118: ...ase half Grease and fit a new crankcase gasket A Check that the guide pin B is in position and fit the other crankcase half Using the assembly tool for the chain saw in question fit the two crankcase halves Pull until the gasket is clamped between the two crankcase halves NOTE Continuing to pull with the assembly tool after the gasket is clamped will damage the crankshaft CRANKCASE AND CRANKSHAFT ...

Page 119: ...the carburettor chamber using the four bolts Fit the following parts A Chain and bar See operating instructions B Starter See page 59 C Electrical system See page 63 D Centrifugal clutch See page 69 E Oil pump See page 77 F Carburettor G Muffler See page 49 H Piston and cylinder See page 111 I Tank unit See page 105 CRANKCASE AND CRANKSHAFT A B Saw 40 and 45 See next page If a crankshaft has been ...

Page 120: ...r the bearing Fit the bearing on the crankshaft by using the assembly tool See Tools A B Continue assembly as described on page 111 CRANKCASE AND CRANKSHAFT Saws 40 and 45 Check the shaft seat s sealing A Fit the shaft seat over the bearing and join the shaft seat at B ...

Page 121: ...rom the oil tank 4 Attach a steel wire to the end of the new bar bolts thread the wire through the oil tank and out through the bolt hole in the crankcase 5 Pull the steel wire until the bolt comes out through its hole 6 Check that the bolt s square shoulder is aligned with its recess in the crankcase Turn the bolt if necessary 7 Pull through the bolt with its nut and spacer between the nut and cr...

Page 122: ...Chain and bar Oil pump Seals fitted in the crankcase Use the dismantling tool for the saw in question and remove the seal as follows 1 Screw the tool into the seal s rubber part 2 Pull the seal from the crankcase by turning the handle Seals fitted on the oil pump or plastic flange Press out the seal using a suitable tool This section describes how to change the seals without splitting the crankcas...

Page 123: ...ysleeveshouldbeusedwhenworking on these saws See Tools 1 Fit the seal using the assembly mandrel 2 The seal should be fitted using the measurements for each saw as shown in the instructions on the next page 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 a...

Page 124: ...A should be as in the table below for resp saws Under the crankcase plane 61 268 4 4 5 mm 272 2 mm 281 288 3 5 mm Measurement B should be as in the table below for resp saws Under the crankcase plane 42 242 246 1 mm 394 5 mm 3120 0 0 5 mm 51 55 1 mm above the crankcase plane Measurement C should be as in the table below for resp saws Under the crankcase plane 51 55 1 mm 394 0 5 mm ...

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