Husqvarna 390 XP W Workshop Manual Download Page 1

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390XP

Workshop manual

Summary of Contents for 390 XP W

Page 1: ...English 1 English 390XP Workshop manual ...

Page 2: ...ake 12 6 Chain catcher 15 7 Muffler 16 8 Start stop switch 17 9 Throttle trigger lockout and spring 18 10 Starter 19 11 Electrical system 21 12 Centrifugal clutch 26 13 Lubrication system 28 14 Carburettor 32 15 Tank unit 39 16 Anti vibration system 41 17 Piston and cylinder 42 18 Crankcase and crankshaft 46 19 Bar bolts 51 20 Troubleshooting 52 ...

Page 3: ...n training new employees 1 4 Modifications In case of modifications made after the publication of this Workshop manual the Manual should be read together with all service information issued concerning the chainsaw in question 1 5 Layout This Workshop Manual can be used in two different ways For the repair of a particular system on the chainsaw Disassembly and Assembly of the entire chainsaw Repair...

Page 4: ...in brake must be fitted before the saw is started otherwise the clutch can come loose and cause personal injury Wear hearing protection when test running Do not use the saw until it has been adjusted so that the chain remains still when idling After test running do not touch the muffler until it has cooled Risk of burn injuries Insufficient lubrication of the chain can result in the chain breaking...

Page 5: ...rkshop Manual This symbol indicates a risk of personal injury if instructions are not followed Choke Switch for hand grip heater Fuel filler Stop switch Screw to adjust chain lubrication Chain oil filler Decompression valve Chain brake Use protective gloves Use protective goggles Introduction and safety regulations ...

Page 6: ... 7 1 5 4 8kW 9600rpm Guide bar length Maximum chain speed Chain pitch Drive link cm inch at maximum power m s mm inch mm inch 390 46 90 18 36 21 4 m s at 9600 rpm 9 52 3 8 1 5 0 058 Spark plug gap Ignition system Air gap Carburettor type mm inch mm inch 390 0 5 0 02 AM50 0 30mm X WJ 116 2 Technical data Technical data ...

Page 7: ... pump capacity Oil tank volume Automatic oil pump Litres US pint Litres US pint 390XP 0 90 1 9 4 20 cm3 min 0 50 1 1 YES Weight without Weight with Hand grip heater Electric carburettor bar and chain bar and chain Watts rpm heater kg lbs kg lbs Watts rpm 390XP XP 7 1 15 6 XP20 8 5kg 18 6 65 10000 YES rpm OIL Technical data ...

Page 8: ...8 English 10 8 3 11 12 13 14 9 1 2a 4 5 6 7 3 Service tools Service tools 2b ...

Page 9: ...cking engine rpm 502 71 14 01 10 Test spark plug Checking the ignition module 502 71 13 01 11 Assembly pliers Assembly of spark plug cap 502 50 06 01 12 Hook for fuel filter Removing fuel filter 502 50 83 01 13 Assembly fixture Dismantling assembling of the chainsaw 502 51 02 01 14 Clutch tool Removing the clutch 502 52 22 01 15 T handle Torx T10 Dismantling assembling of the chainsaw 588 52 41 01...

Page 10: ...th two stroke oil Lubricate with chain oil Lubricate with grease 4 Service data Service data 4 mm 8 9 Nm 4 mm 8 10 Nm 4 mm 8 10 Nm 4 mm 4 5 5 5 Nm 4 mm 4 5 5 5 Nm 1 1 5 Nm 4 mm 4 5 5 5 Nm 4 mm 4 5 5 5 Nm 13 mm 15 Nm 4 mm 8 10 Nm 5 mm 12 14 Nm 4 mm 8 10 Nm 20 Nm 1 1 5 Nm 1 2 Nm 1 2 Nm 1 2 Nm 1 2 Nm 3 4 Nm 1 2 Nm ...

Page 11: ...25 Nm 4 mm 6 8 Nm 4 mm 8 10 Nm 13 mm 12 14 Nm 19 mm 15 Nm 4 mm 8 10 Nm 4 mm 4 5 5 5 Nm 4 mm 4 5 5 5 Nm 4 mm 2 5 5 Nm 4 mm 4 5 5 5 Nm 4 mm 4 5 5 5 Nm 3 mm 1 1 5 Nm T27 6 7 Nm 4 mm 4 5 5 5 Nm 4 mm 4 5 Nm 4 mm 3 5 4 5 Nm 4 mm 6 8 Nm 0 5 1 Nm 0 5 1 Nm ...

Page 12: ...ual 2 Disassemble the centrifugal clutch Refer to chapter Centrifugal clutch in the Workshop manual 3 Push the hand guard forward so that the chain brake is engaged See fig 1 4 Remove the hand guard two screws Note the sleeve on the starter side See fig 2 5 Remove the chain guide plate A See fig 1 6 Remove the locking ring C with washer D and lift up the clutch drum E with needle bearing F and cha...

Page 13: ...the lever I with a screwdriver See Fig 7 10 Remove the pressure spring by freeing the back end with a screw driver See fig 8 11 Remove the toggle joint J with attached brake strap See fig 8 12 Remove the brake strap from the toggle joint 13 Take out the retaining bush H with spring See fig 5 Carefully clean and examine all parts Parts must be replaced if cracked or show signs of other defects Alwa...

Page 14: ...he clutch tool Note left hand thread See fig 11 11 Remove the piston stop and fit the spark plug and put on the ignition cable 12 Grease in the needle bearing before fitting Fit the clutch drum E with needle bearing F and chain drive sprocket G See fig 3 13 Fit the washer D and locking ring C See fig 4 14 Fit the cylinder cover chain and bar See Operators Manual For this test the engine must not b...

Page 15: ...ve the clutch cover 2 Disassemble the bar and chain 6 2 Cleaning and inspection Inspect the chain catcher and replace it if it is damaged See figure 1 6 3 Assembly 1 Fit the bar and chain 2 Adjust the tension of the chain 3 Fit the clutch cover See 4 Service data on page 10 Fig 10 Fig 11 ...

Page 16: ...sket has to be fitted correctly against the muffler 7 2 Cleaning and inspection Clean all components and do a check of 1 That the spark arrester is intact 2 That the muffler and muffler mounting are not cracked or in any way defect 3 That the gasket is undamaged 7 3 Assembly 1 Clean the contact surfaces of the gasket cooling plate and cylinder 2 If the chainsaw is fitted with a spark arrester refi...

Page 17: ...s follows 0 pressed in less than 0 1 ohm 1 pressed in more than 1000 ohm 8 3 Assembly The symbol stop marking should be mounted to the rear hand grip during assembly The earth lead is fitted in the upper or lower connection See fig 2 8 4 Function check Clean the mating surfaces and do a check of the resis tance as follows Measure the resistance by connecting a multimeter to the blue cable and the ...

Page 18: ...B with a driver See fig 1 and 4 5 Remove the throttle cable and lever See fig 4 9 2 Cleaning and inspection Clean all components and do a check of the following 1 That the throttle cable and lever are undamaged and run easily 2 That the lock activation mechanism is not worn See fig 2 9 3 Replace a defect throttle cable Attach the wire to the throttle trigger Pull the wire through the handle 9 4 As...

Page 19: ...clockwise until the tension on the pulley is released 4 Remove the central bolt and take out the washer and starter pulley See fig 3 5 If the starter cord is to be replaced cut it off and pull out the ends from the handle and starter pulley with pointed pliers 6 If the spring is to be replaced remove the old spring 10 2 Cleaning and inspection 1 Clean all components 2 Do a check of the following S...

Page 20: ...bolts See fig 1 7 Wind the cord onto the starter pulley and rotate the pulley clockwise until the cord is correctly tensioned See fig 6 3 If a new cord is to be fitted push the free end in the hole in the starter pulley Take hold of the end with pointed pliers inside the pulley and pull up the cord See fig 5 4 Grease the starter pulley bearing and spring and fit the pulley on the spindle Turn gent...

Page 21: ...bolts and lift off the ignition module B See fig 1 5 Remove the two pawls E for the starter See fig 1 and fig 6 6 Remove the spark plug and fit the piston stop Refer to 3 Service tools on page 8 in the spark plug hole See fig 2 7 Release the flywheel nut Unscrew the nut until it comes level with the outer end of the shaft thread See fig 3 8 Fit the flywheel puller See 3 Service tools on page 8 Tig...

Page 22: ... its bolts See fig 8 6 Turn the flywheel so that its magnet G comes opposite the ignition module See fig 7 7 Insert the feeler gauge H 0 3 mm between the ignition module and the flywheel magnet The clearance only applies to the two lower pegs on the ignition module See fig 7 and 8 8 Push the ignition module against the flywheel and tighten the bolts Refer to 4 Service data on page 10 9 Fit the cab...

Page 23: ...nt hand grip with heating element Measure the resistance in the front hand grip element between points A and B See fig 10 The ohmmeter should show 3 4 ohms If the value is higher replace the hand grip Generator Measure the resistance in the generator between the points G and H See fig 10 The ohmmeter should show 0 3 1 3 ohms If the value is higher replace the genera tor Switch Release one of the c...

Page 24: ...11 2 Remove the generator by unscrewing the three bolts See fig 12 3 Release the cable from the switch and remove the generator 4 Fit the new generator as shown in fig 13 and tighten the bolts Refer to 4 Service data on page 10 5 Position the cable as shown in fig 13 and connect it to the switch 6 Refit the flywheel and the starter 11 2 3 Replacing the switch 1 Remove the switch and disconnect the...

Page 25: ... hand grip 1 Release the two cable clips beside the spring See fig 16 2 Remove the five bolts A B C and D which hold the front hand grip See fig 15 3 Fit the new front hand grip by screwing in the five bolts A B C and D Tighten the bolts See fig 15 and also refer to 4 Service data on page 10 4 Connect the two cables See fig 16 ...

Page 26: ...tors Manual 2 Remove the chain guide plate by unscrewing the bolt A See fig 1 3 Remove the locking ring B with washer and lift up the clutch drum C with needle bearing D and chain drive sprocket E See fig 2 4 Remove the spark plug and fit the piston stop Remove the clutch with the clutch tool Refer to 3 Service tools on page 8 Note left hand thread Screw in the direction of the arrow as shown in f...

Page 27: ...face on the crankshaft undamaged 5 The friction surface on the clutch drum should be intact and the bearing surface undamaged 12 3 Assembly When assembling the centrifugal clutch the chain brake must be in the off position 1 Fit the clutch shoes on the hub and fit the springs with circlip pliers See fig 4 2 Fit the clutch hub on the crankshaft and tighten with the clutch tool Note Left hand thread...

Page 28: ...ication system consists of the following parts Oil pump Suction hose with filter Oil hose with integrated filter Fig 1 Fig 2 Fig 3 Lubrication system Fig 1 Fig 2 Fig 3 B A C H G F Fig 1 Fig 2 Fig 3 B A C H G F Fig 1 Fig 2 Fig 3 B A C H G F 5 Use pointed pliers and pull up the suction pipe C with filter See fig 3 13 1 Disassemble the oil pump and pipe 1 Empty and clean the oil tank 2 Disassemble th...

Page 29: ...E 4 The worm gear of the oil pump drive should be undamaged See fig 6 5 The oil pipe should be free from unwanted materials and the filter clean 6 The oil pipe should be free from unwanted materials and its seals undamaged 13 2 Cleaning and inspection Clean all parts including the pump and oil pipe mounts in the crankcase and do a check of the following 1 The taper on the adjuster screw E should n...

Page 30: ...parts The centrifugal clutch Refer to Centrifugal clutch chapter The other parts of the saw Refer to the Operators Manual Adjust the pump feed rate Refer to Adjusting the pump feed rate chapter Refill with chain oil and check the lubrication Refer to the Operators Manual 13 4 Adjusting the pump feed rate The pump feed rate is adjusted with the adjuster screw E in fig 8 The table shows the number o...

Page 31: ...English 31 Lubrication system ...

Page 32: ...d for the actual speed and power output The mixing venturi B contains the choke throttle valve and diffuser jets Here air is mixed with the fuel to give a fuel air mixture that can be ignited by the ignition spark Fig 2 Fig 1 Fig 3 WARNING The fuel used in the chainsaw has the following hazardous properties 1 The fluid and its fumes are poisonous 2 Can cause skin irritation 3 Is highly inflammable...

Page 33: ...the throttle valve H is closed Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied through the dif fuser jet G Fig 6 Fig 5 Fig 7 Fig 4 Fig 4 D E F G Fig 5 H G Fig 6 H F G Fig 7 E F G Fig 4 D E F G Fig 5 H G Fig 6 H F G Fig 7 E F G Fig 4 D E F G Fig 5 H G Fig 6 H F G Fig 7 E F G Fig 4 D E F G Fig 5 H G Fig 6 H F G Fig 7 E F G In the part throttle mode f...

Page 34: ...e Fig 8 Fig 9 Fig 10 Fig 8 Fig 9 Fig 10 A D D C B H G F E I J K L A D D C B H G F E I J K L A D D C B H G F E I J K L 7 Remove the cover E over the metering unit and carefully remove the metering diaphragm F and gasket See fig 9 8 Remove the screw G and take out the needle valve H with lever spindle and spring See fig 9 9 Remove the cover I over the pump unit and carefully remove the gasket J and ...

Page 35: ...See Figure 12 That the fuel screen is intact and clean That the inlet manifold is undamaged Fig 12 Fig 12 Fig 11 M M 14 5 Cleaning and inspection Clean all units with clean petrol WARNING Do not direct the compressed air jet towards your body or any person when using compressed air Air can go through the skin into the blood and result in mortal danger Use compressed air to dry the petrol on the co...

Page 36: ...ting problems 1 If the throttle and choke valves together with levers and springs are removed they must be refitted Lubricate the spindle bearings with light oil 2 Fit the high and low speed screws and springs Note Do not fully tighten the screws This will damage the seats and needle tips 3 Fit the fuel filter L by using the handle of a small screwdriver See fig 13 4 Fit the pump diaphragm K gaske...

Page 37: ...uel intake of the carburettor 3 Lower the carburettor into a beaker of water 4 Pump up the pressure to 50 kPa 0 5 bar and squeeze together the tube 5 No leakage is permitted If there is a leak refer to the table below Leakage at Fault with Diffuser jets Leakage in impulse tube Ventilation hole on me tering unit Needle valve Pump diaphragm Control diaphragm 14 8 Assemble on the chainsaw See fig 18 ...

Page 38: ...e carburettor involves adjusting the engine to the local conditions for example climate altitude fuel and type of 2 stroke oil The carburettor is equipped with three adjustment op tions L Low speed jet H High speed jet T Idling adjustment The L and H jets adjust the fuel flow to match the air flow that the throttle valve opening allows Turning them clockwise makes the fuel and air mixture weaker l...

Page 39: ... bolts C D E and F See fig 2 7 Remove the bolts H J and K from the flywheel side See fig 3 8 Remove the stop switch and the disconnect the leads If the chainsaw is fitted with hand grip heating discon nect the switch and leads CAUTION Take care not to damage the fuel hose return hose tank vent hose or throttle cable 9 If the tank guard chain deflection break G is damaged it must be replaced See fi...

Page 40: ... Fig 7 Fig 4 Fig 5 Fig 7 H Fig 6 B A Fig 4 Fig 5 Fig 7 H Fig 6 B A Fig 4 Fig 5 Fig 7 H Fig 6 B A 15 3 Assembly 1 If the chainsaw is fitted with hand grip heating fit the heating element if it has been removed 2 To fit a new fuel pipe Lightly oil in one half of the new fuel pipe Press the oiled part through the hole in the tank unit Allow 80 85 mm to protrude on the outside See fig 4 Turn the pipe ...

Page 41: ...cover See the Operators Manual Tank unit Refer to 15 Tank unit on page 39 2 Remove the spring on the cylinder with a 4 mm Allen key See fig 1 Fig 1 Fig 2 Fig 1 Fig 2 16 2 Cleaning and inspection Clean and inspect all parts 16 3 Assembly 1 Remove the springs on the cylinder with a 4 mm Allen key See fig 1 2 Assemble the following parts Tank unit Refer to 15 Tank unit on page 39 Cylinder cover Refer...

Page 42: ... score marks See figure 3 3 That the piston is free of score marks Minor scratches can be polished off with fine emery paper 1 Disassemble the following parts Cylinder cover Spark plug Carburettor Muffler 2 Unscrew the anti vibration spring B from the cylinder See fig 1 3 Unscrew the four bolts on the cylinder C See fig 1 4 Carefully lift up the cylinder CAUTION Be careful so that dirt and unwante...

Page 43: ...ression valve A Connect the pressure testing device Refer to pos 3 3 Service tools on page 8 to the decompres sion valve B Pressurize to 80 kPa 0 8 bar C Wait 30 seconds D The pressure must not fall below 60 kPa 0 6 bar Faults and causes Score marks on the piston See Figure 6 1 Incorrect carburettor setting Too high over speed 2 Too low octane fuel 3 Too low or incorrect oil in the fuel Carbon bui...

Page 44: ...e Data 9 Fit the anti vibration spring B on the cylinder See fig 11 Tighten the bolt with correct torque See Service Data 10 Insert the spark plug and do a pressure test Refer to the Leakage testing chapter Assemble the following parts Muffler Carburettor Cylinder cover See the Operators Manual 11 If a new piston and or cylinder is installed in the chainsaw should be run in for 3 4 hours with the ...

Page 45: ...ecompression valve and crankshaft seals 10 Assemble Carburettor Muffler Fig 12 Fig 13 Fig 14 Fig 12 Fig 13 Fig 14 Fig 12 Fig 13 Fig 14 Fig 12 Fig 13 Fig 14 17 4 Leakage testing The following parts must be removed to pressure test the crankcase and cylinder Carburettor Muffler To do a pressure test 1 Remove the support ring in the intake manifold 2 Fit cover plate Refer to pos 2a 3 Service tools on...

Page 46: ...NING The crankcase halves are hot and can cause burn injuries Wear protective gloves 3 If necessary remove the seal on the flywheel side See fig 2 pos A Use flywheel removal tool Refer to pos 7 3 Service tools on page 8 See fig 2 4 Remove the six bolts on the flywheel side See fig 4 1 Before the crankcase can be separated the following parts must be disassembled Chain and bar Refer to the Operator...

Page 47: ...t from the crankcase half 8 If the crankshaft bearing should remain on the crankshaft remove it with puller Refer to pos 4 3 Service tools on page 8 9 If necessary remove the following parts A Bark gripper B Rubber stop A See fig 5 18 2 Cleaning and inspection NOTE If the bearings are mounted in the crankcase be careful to avoid dirt and unwanted materials getting in Clean all parts and scrape of ...

Page 48: ...alf of the clutch side the bearing should be fitted flush with the inside of the crankcase B See fig 9 C Allow the crankcase half to cool before continuing work D Fit the rubber stop A See fig 5 E Fit the oil filler cap 2 When fitting new seals the sealing surfaces should be greased in When fitting the seal on the flywheels side use tool Refer to pos 20 3 Service tools on page 8 The seal on the cl...

Page 49: ...lts Tighten them alternately Tighten them finally to 8 Nm See fig 14 7 Cut the gasket at the level of the cylinder s seating plane 8 Fit the carburettor space bottom with the four bolts Tighten the bolts with correct torque Refer to 4 Service data on page 10 9 Assemble the following parts A Tank unit B Piston and cylinder C Muffler D Carburettor E Lubrication system F Centrifugal clutch G Electric...

Page 50: ...nd crankshaft 3 Tap in the new seal with the drift See fig 17 Install the parts Refer to the disassembly instructions in the chapter Crankcase and crankshaft 18 4 Seals 1 To replace the seals on the crank shaft remove the following parts first On the flywheel side Starter Flywheel Generator where appropriate On the clutch side Chain and bar Refer to Operators manual Chain guide plate Centrifugal c...

Page 51: ...o its hole 3 Pull out the bolt with its nut and shim between the nut and crankcase 4 Make sure that the square head of the bolt comes in its recess in the crankcase If needed turn the bolt 5 Refill with chain oil Fig 1 Fig 15 Fig 16 Fig 17 19 2 Disassembly 1 Drain the chain oil 2 Push in the old bar bolt from outside so that it drops in the oil tank 3 Remove the bolt from the oil tank 19 3 Cleanin...

Page 52: ...ooting The different faults which can occur on the chainsaw are divided into four groups Within each group possible operating faults are listed to the left while the probable fault alternatives are listed to the right The most likely fault is listed first Starting Difficult to start Air filter blocked Choke does not work Worn choke axle Worn choke valve Blocked fuel filter Blocked fuel line Piston...

Page 53: ...p diaphragm Faulty diffuser jet Acceleration and retardation Does not accelerate Blocked air filter Tank venting clogged Blocked fuel filter Blocked fuel line Loose or faulty fuel hose Blocked impulse channel The cover on the carburettor pump side is loose Faulty pump diaphragm Leaking inlet hose rubber Loose carburettor mounting Control system set too low Control system incorrectly as sembled Con...

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