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Husqvarna 362XP, Workshop Manual

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Husqvarna 362XP Workshop Manual Download Page 5

SYMBOLS

English – 3

Symbols on the saw

Symbols in this manual

!

This symbol indicates a risk of personal
injury if instructions are not followed.

Choke

Switch for hand grip heating

Fuel filler

Stop button

Chain lubrication adjuster

Chain oil filler

The markings shown below are moulded into the chainsaw
casing.

STOP

Summary of Contents for 362XP

Page 1: ...Workshop manual 101 90 61 26 362XP 365 372XP ...

Page 2: ...ta 4 Service tools 6 Trouble shooting 8 Service information 10 Safety equipment 12 Recoil starter 16 Electrical system 18 Centrifugal clutch 22 Lubrication system 24 Carburettor 26 Tank unit 35 Anti vibration system 37 Piston and cylinder 38 Crankcase and crankshaft 42 ...

Page 3: ... to avoid problems the manual should always be read together with all service announcements that apply to the specific model of chainsaw Changes Arrangement Repair of a specific sub assembly When a specific sub assembly on the chainsaw is to be repaired proceed as follows 1 Look up the page referring to the relevant sub assembly 2 Carry out the steps Dismantling Cleaning and inspection Reassembly ...

Page 4: ...sting the chainsaw Do not use the saw before it has been adjusted so that the chain is still when idling Aftertesting donottouchthesilenceruntilithascooled Risk for burns Inadequate lubrication of the chain can result in the chain breaking which can cause serious or life threatening injury Make sure that the starter recoil spring does not fly out and cause personal injury If the spring is tensione...

Page 5: ...anual This symbol indicates a risk of personal injury if instructions are not followed Choke Switch for hand grip heating Fuel filler Stop button Chain lubrication adjuster Chain oil filler The markings shown below are moulded into the chainsaw casing STOP ...

Page 6: ...rkplug gap Ignition system Air gap Carburettor type mm inches mm inches 362XP 0 5 0 02 FHP CD 0 3 0 01 Walbro HD6B 365 0 5 0 02 FHP CD 0 3 0 01 Zama C3M EL2B 372XP 0 5 0 02 FHP CD 0 3 0 01 Walbro HD6B Guidebar length Chain speed at max power Chain pitch Drive link gauge and 9 600 rpm cm inches m s mm inches mm inches 362XP 33 60 13 24 21 4 8 25 0 325 1 5 0 058 9 52 3 8 365 38 61 15 24 20 7 9 52 3 ...

Page 7: ...oil pump Litres US pints cm3 min Litres US pints 362XP 0 77 1 63 4 20 0 42 0 89 Yes 365 0 77 1 63 4 20 0 42 0 89 Yes 372XP 0 77 1 63 4 20 0 42 0 89 Yes Weight without bar and chain Weight with bar and chain Hand grip heater kg lbs kg lbs Watts rpm 362XP 6 0 13 2 15 7 1 15 6 65 10 000 20 7 5 16 5 362XPG 6 2 13 7 15 8 2 18 1 65 10 000 20 8 7 19 2 365 6 0 13 2 15 7 1 15 6 20 7 5 16 5 372XP 6 1 13 4 1...

Page 8: ...6 English SERVICE TOOLS 1 2 4 5 10 11 12 13 14 6 7 9 8 3 15 17 18 ...

Page 9: ...55 01 13 Extractor Removing flywheel side crankcase seal 504 91 40 01 14 Assembly tool Reassembling crankshaft 502 50 30 15 15 Feeler gauge air gap Setting ignition unit 502 51 34 02 17 Extractor Removing large AV springs 502 52 18 02 18 Tachometer Setting the carburettor 502 71 14 01 19 Test spark plug Testing ignition unit 502 71 13 01 20 Clutch tool Clutch dismantling and assembly 502 52 22 01 ...

Page 10: ...pivot stiff Throttle cable sticking Defective throttle return spring Bent throttle stop Faulty diffuser jet Adjust L screw Worn needle valve Needle valve set too high Worn needle valve lever Leaking control diaphragm cover plate Needlevalveassemblysticking Worn needle valve Leaking control diaphragm cover plate Needlevalveassemblysticking Worn needle valve lever Faulty diffuser jet Fuel filter blo...

Page 11: ... filter Faulty pump diaphragm Faulty diffuser jet Will not run at full throttle Low power Will not four stroke High rpm Adjust H screw Blocked air filter Blocked fuel tank ventilator Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake rubber Loose carburettor m...

Page 12: ...ish Lubricate with two stroke oil Lubricate with chainsaw chain oil Lubricate with grease Figures next to components which are attached using bolts give the appropriate tightening torques in Nm Key to diagrams 14 10 10 15 8 6 8 5 ...

Page 13: ...SERVICE INFORMATION English 11 4 35 4 4 4 10 4 6 6 1 5 15 15 10 ...

Page 14: ...that the chain brake is on See fig 1 3 Unscrew hand guard two bolts Note sleeving on the starter side See fig 2 4 Remove bolt A and chain guide plate See fig 1 5 Undo the four bolts B and remove the chain brake assembly cover See fig 1 6 Press down the retaining bush C and remove the lever arm D See fig 3 7 Removethepressurespringbyfreeingtherearwardend with a screwdriver See fig 4 8 Remove the to...

Page 15: ... be checked in accordance with the following instructions Checking brake operation E C F Fig 6 Assemble the chain brake as follows 1 Reattach the toggle joint and brake strap See fig 5 2 Grease the toggle joint E moving parts and locate the assembly in the chainsaw See fig 6 3 Grease and insert the lever arm D See fig 3 4 Greaseandinserttheretainingbush C andspring See fig 3 5 Locate the chain bra...

Page 16: ...pped with a spark guard this should be removed See fig 9 Fig 9 Fig 10 Chain catcher Inspection Clean all components and check the following 1 The spark guard is undamaged 2 The silencer and silencer mount are not cracked or have any other defects 3 The gasket is undamaged Reassembly 1 Clean the gasket cooling plate and cylinder contact surfaces 2 If the chainsaw is equipped with a spark guard refi...

Page 17: ...ttle lever and cable and locate them in the tank unit Ensure that the cable lever arm E is between the lip D and the under side of the hand grip See fig 15 2 Press home the throttle lever pivot B with the help of a driver See fig 12 3 Locate the spring in the recess in the throttle lock Hold the spring in place and locate the throttle lock in the recess in the hand grip See fig 16 4 At the same ti...

Page 18: ...ack towards the centre and move freely WARNING Make sure that the recoil spring does not fly up and cause personal injury WARNING If the recoil spring is tensioned when the cord pulley is removed the spring can fly up and cause personal injury 4 Remove the central bolt and take out the washer and cord pulley See fig 3 5 If the starter cord is to be replaced cut it off and pull out the ends from th...

Page 19: ... pull the cord through See fig 5 4 Greasethecordpulleybearingandrecoilspringandthen fit the pulley onto the spindle Turn the pulley gently backwards and forwards until the recoil spring catches on the stop in the housing 5 Fitthewasherandcentralbolt Seefig 3 Tightenthebolt to 4 Nm 6 Pull the cord out through the hole in the housing and attach the handle with a double knot See fig 5 7 Wind the cord...

Page 20: ... starter See fig 1 6 Remove the spark plug and fit the piston stop tool in the spark plug hole See fig 2 7 Release the flywheel nut Undo the nut until it is in line with the thread on the shaft outer end See fig 3 8 Attachtheflywheelpuller TightendownthetwoM5x25 bolts approx 10 turns Tighten the central bolt while preventingrotationwiththeholdingtool untiltheflywheel comes loose See fig 4 9 Remove...

Page 21: ...learance applies only to the two lower pegs on the ignition module See figs 6 and 7 6 Push the ignition module towards the flywheel and tighten the bolts to 4 Nm 7 Fitthecableguide D andpressintheHTleadintoplace Remove the piston stop and connect the HT lead to the spark plug 8 Pulloutthebluelead threaditundertheHTleadatFand push home the cable clip onto the ignition module See fig 1 9 Press the b...

Page 22: ...sure the resistance in the front handle heating element The metershouldread3 4 Ifthereadingishigher replace the front hand grip 6 Connect the ohmmeter as shown in fig 11 and measure the resistance in the generator The ohmmeter should readbetween0 9 1 3 Ifthereadingishigherorlower replace the generator 7 Disconnect one of the connections to the on off switch and connect the ohmmeter as shown in fig...

Page 23: ...ad is seated in the recess in the plate as shown in fig 15 Tighten the bolts to 5 Nm 8 Refit the components from point 1 Replacing the heating element in the rear hand grip tank unit 1 Disconnect the two cable clips beside the springs 2 Remove the five bolts which secure the front hand grip 3 Fit the new hand grip and replace the five fixing bolts tightening them to 4 Nm 4 Reconnect the two leads ...

Page 24: ...eel E See fig 2 4 Remove the spark plug insert the piston stop tool and unscrew the clutch hub with the clutch tool Note left hand thread Turn in the direction of the arrow as shown in fig 3 The following points 5 7 describe the dismantling of the clutch hub 5 Usingascrewdriver leverinthelipofthespringsuchthat the spring sticks out a little on the other side See fig 4 6 Stretch out the springs wit...

Page 25: ...surface are undamaged During reassembly of the centrifugal clutch the chain brake should be in the off position Reassembly Fig 5 Fig 6 NOTE The clutch springs should not be opened out more than necessary Risk of deformation 1 Locatetheclutchshoesonthehubandfitthespringswith the help of circlip pliers See fig 4 2 Screwtheclutchhubontothecrankshaftandtightenwith the clutch tool Note left hand thread...

Page 26: ...ok Centrifugal clutch See page 22 Chain brake See page 12 3 Unscrew the drive wheel See fig 1 4 Use a screwdriver and lift the oil pipe forward atA Lift up the pipe and pull it out of the oil pump See fig 2 5 Remove the two bolts B and lift the oil pump from the crankcase See fig 2 6 Use pointed pliers to pull free the suction pipe C and sieve See fig 3 7 Remove the clip D and unscrew the adjuster...

Page 27: ...elow 11 Refillwith chainoilandchecklubrication Seeinstruction book Clean all components including the pump and oil pipe mounts in the crankcase and check the following 1 The taper on the adjustment screw E does not show signs of wear See fig 5 2 The pump piston H eccentric face does not show signs of wear See fig 5 3 The pump piston pinion is undamaged See fig 5 4 The oil pump drive worm gear is u...

Page 28: ...ne speed and power demand is metered In the mixing venturi B the choke throttle butterfly valve and diffuser jets are located Air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark In the pump unit C fuel is pumped from the fuel tank to the meteringunit Onesideofthepumpdiaphragmisconnected to the crankcase and pulses in time with the pressure changes in the...

Page 29: ...uel is sucked more easily from the diffuser jets E F and G The throttle butterfly H is partially open In idling mode fig 5 the throttle butterfly H is closed Air is sucked through an aperture in the butterfly and a small amount of fuel is supplied through the diffuser jet G Inpartthrottlemode fig 6 thethrottlebutterfly H ispartially open Fuel is supplied through the diffuser jets F and G In full t...

Page 30: ...ing a welding rod or similar 6 Loosen the air filter holder and lift off the carburettor Leave the filter holder in the carburettor space Removal Fig 8 Fig 9 Fig 10 7 Remove the top cover E of the metering unit and carefullyremovethemeteringdiaphragm F andgasket See fig 9 8 Undo the screw G and take out the needle valve H together with the lever arm spindle and spring See fig 9 9 Remove the cover ...

Page 31: ...blocked See figs 11 and 12 and check the following 1 The gaskets pump diaphragm and metering diaphragm are undamaged Fig 12 Fig 11 M M WARNING When using compressed air the air jet should never be pointed towards the body Air can be forced into the blood stream which can cause fatality 2 There is no play in the throttle and choke butterflies 3 The needle valve and its lever arm are not worn at M i...

Page 32: ...Position the fuel filter L with the help of the handle of a small screwdriver See fig 13 4 Fitthepumpdiaphragm K gasket J andcover I ofthe pump unit See fig 13 5 Fittheneedlevalve H withleverarm spindleandspring and tighten the screw G See fig 14 6 Checkwitharulerorsimilarthattheleverarmislevelwith thecoverface Seefig 15 Ifnecessary theleverarmcan be bent slightly 7 Fit the metering diaphragm F wi...

Page 33: ...f water 4 Pump up the pressure to 50 kPa 0 5 bar and clamp the pump tube 5 There should be no leakage If leakage occurs refer to the table below Leakage at Fault with Diffuser jets Needle valve Leakage in impulse tube Pump diaphragm Ventilation hole above Control diaphragm metering unit Refitting to the chainsaw See fig 18 1 Loosen the air filter holder and position the carburettor in place in the...

Page 34: ...to a weaker mixture than the basic settings state The recommended max overspeed must not be exceeded Note Ifthechainturnsatidlingspeed theT screwshouldbe turned anti clockwise until the chain stops Fine adjustment When the chainsaw is run in fine adjustment of the carburettor should be carried out Firstly adjust the L jet screw then the idling screw T and finally the H jet screw The following are ...

Page 35: ...en turn the H screw anti clockwise 1 4 turn Run the saw againatfullthrottlefor10secondsandlistentothedifference inthemax overspeed Repeatthisprocedureagainwiththe H screw turned a further 1 4 turn anti clockwise You have now run the saw at settings H 0 H 1 4 and H 1 2 from the base settings At full throttle the motor will have sounded different at each setting The H screw is correctly adjusted whe...

Page 36: ...ments within the limits the caps allow may be necessary to achieveoptimumperformance SeetheOperator smanual Basic adjustment for EPA carburettors After replacing the carburettor or high speed and or low speedneedleonanEPA TheUSEnvironmentalProtection Agency certifiedproductabasicadjustmentmustbecarried outasdescribedbelowinordertomeettheEPA requirements Thistoachieveaslowemissionsaspossible Thisin...

Page 37: ... from the flywheel side See fig 3 8 Lift the motor unit slightly and using pliers push off the cable clips from their respective switches If the saw is equipped with hand grip heating disconnect the leads from on off switch 9 Lift the motor unit and turn the tank unit slightly to the flywheel side so that the fixed travel limiter comes free Lift off the tank unit 10 Ifnecessary detachthefronthandg...

Page 38: ...ed it should be refitted before the tank unit and motor unit are reassembled See page 15 5 Lift the motor unit over the tank unit and push the fuel line and throttle cable into their holes in the bottom of the carburettor space 6 Reconnect the leads to the stop switch 7 Turn the tank unit a little towards the flywheel side so that the fixed travel limiter is in the correct position 8 Refit the bol...

Page 39: ...G The fuel that is used in the chainsaw poses the following hazards 1 Thefluidanditsfumesarepoisonous 2 Can cause skin irritation 3 Is highly inflammable 1 Remove the following components Chain and guide bar See instruction book Cylinder cover See instruction book Tank unit See page 35 2 Detach the springs from the cylinder with the help of a 4 mm Allen key See fig 1 3 Detach the springs from the ...

Page 40: ...nkcase opening immediately with paper or clean rag See fig 2 7 Removeoneofthepistoncirclips pressoutthegudgeon pin and remove the piston See fig 2 8 Remove the needle roller bearing from the connecting rod little end 9 Unscrew and remove the decompression valve D See fig 1 10 Undo the clamp bolt and remove the inlet manifold Fig 1 Fig 2 Fig 3 Clean all components scrape off the remains of any gask...

Page 41: ...nlet manifold is undamaged 8 Pressure test the decompression valve as follows See also fig 5 A Connect tool 502 50 38 01 to the decompression valve B Pump up the pressure to 80 kPa 0 8 bar C Wait 30 seconds D The pressure should not be less than 60 kPa 0 6 bar Score marks on the piston Fig 6 1 Incorrect carburettor settings Excessive overspeed 2 Too low octane fuel 3 Too little or incorrect oil in...

Page 42: ...e cylinder 7 Fit the four cylinder bolts C and tighten them in rotation Finally tighten them to 10 Nm See fig 11 8 Refit the decompression valve D See fig 11 Tighten it to 15 Nm 9 Attach the anti vibration springs B to the cylinder See fig 11 Tighten the bolts to 10 Nm 10 Push home the impulse pipe A in the hole on the inlet manifold See fig 11 11 Fitthesparkplugandcarryoutpressuretestingaccording...

Page 43: ...2 71 39 01 to the inlet manifold and exhaust port See figs 12 and 13 2 Connect tool 502 50 38 01 to the cover plate on the inlet manifold See fig 14 The decompression valve should be closed 3 Close off the pipe to the impulse channel 4 Pump up the pressure to 80 kPa 0 8 bar 5 Wait 30 seconds 6 The pressure should not be less than 60 kPa 0 6 bar 7 Leakage can occur from the decompression valve and ...

Page 44: ... 502 51 61 01 as shown in fig 3 and remove the clutch side crankcase half 6 Remove the flywheel side crankcase half in the same way as for point 5 above 7 Ifrequiredremovetheseals Usetools 5025055 01and 504 91 40 01 See fig 4 Crankcase and crankshaft Dismantling 1 Before the crankcase can be split the following components must be removed A Chain and guide bar See instruction book B Recoil starter ...

Page 45: ...n screw B Guide bar bolts C Bark gripper Cleaning and inspection NOTE Ensure that no dirt or foreign particles enter the bearings if they are in place in the crankcase Clean all components and scrape off the remains of gasket material from the crankcase half mating surfaces Check the following 1 The big end bearing does no have any radial play Axial play is acceptable 2 The big end bearing does no...

Page 46: ...he bearings D Refit the rubber stop A See fig 9 E Refit the oil filler cap 2 If replacement crankcase seals are to be fitted grease the seal surfaces and tap them home using tools 502 52 20 01 and 502 52 21 01 See fig 10 The seals can also be fitted with the crankshaft in place NOTE Ensure that the connecting rod does not jam against the crankcase when the crankcase and crankshaft are reassembled ...

Page 47: ... Tank unit See page 36 B Piston and cylinder See page 40 C Silencer See page 14 D Carburettor See page 31 E Lubrication system See page 25 F Centrifugal clutch See page 23 G Electrical system See pages 19 21 H Recoil starter See page 17 I Chain and guide bar See instruction book 10 If a new crankshaft has been fitted the saw must be run in for 3 4 hours at the carburettor base settings H 1 and L 1...

Page 48: ...h side Chain and guide bar See instruction book Chain guide plate See page 12 Centrifugal clutch See page 22 Oilpump See page 24 Guide bar bolts Fig 15 Fig 16 Fig 17 1 Drain out the chain oil 2 Knockthroughtheoldguidebarboltsothatitfallsintothe oil tank 3 Remove the bolt from the oil tank 4 Fasten a steel wire to the thread of the new bolt thread thesteelwireintotheoiltankandoutthroughthebolthole ...

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