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Husqvarna Jonsered CS 2245, Workshop Manual

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Husqvarna Jonsered CS 2245 Workshop Manual Download Page 38

38

 – English

Repair instructions

Assembly
Maintain a high level of cleanliness when assem-
bling the carburettor. The slightest contamination 
can result in running problems.

1.  If the throttle and choke valves, together with 

levers and springs were removed, they should 
be refi tted. The spring is tensioned 1-2 turns. 
Lubricate the shaft bearings with light oil.

2.  Fit the high and low speed needles and 

springs.Note! Do not fully tighten the screws. 
This will damage the seats and needle tips.

3.  Fit the fuel fi lter (J) by using the handle of a 

small screwdriver. (see fi gure 33)

4.  Fit the pump diaphragm (M), gasket (L) and 

cover (K) on the pump unit. (see fi gure 33)

J

M

L

K

5.  Fit the needle valve (E) with lever (D), pin and  

spring and tighten the screw (F). Fit welch plug 
(Q) (see fi gure 34)

.

6.  Check using a ruler or the like that the lever 

is level with the assembly plane on the cover. 
The lever arm can be bent if necessary.

 

(see 

fi gure 35)

7.  Fit the control diaphragm (B) with gasket (C) 

and cover (A) on the metering unit. (see fi gure 
36) 

8.  Fit the throttle valve (U) on the shaft (R). Fit 

lever (S) on the shaft (R) parallel with the 
ordinary throttle valve.

 

The valve housing (T) 

is secured in the air fl ange using two screws. 
(see fi gure 32)

9.  Carry out a pressure test.

Fig 34

Fig 33

Fig 35

Fig 36

Summary of Contents for Jonsered CS 2245

Page 1: ...Workshop manual 510 09 69 26 ...

Page 2: ......

Page 3: ... 7 Technical Specifications 10 Service tools 12 Service data 14 Safety equipment 16 Repair instructions 24 Carburettor 33 Fault tracing 53 Contents Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice ...

Page 4: ...ications 7 Numbering 7 Safety 7 Special Instructions 8 Structure 7 Target group 7 Tools 7 M Muffler 19 Assembling the muffler 19 Dismantling the muffler 19 O Oil pump and screen 31 Assembling the oil pump and screen 32 Cleaning and inspection 31 Dismantling the oil pump and screen 31 P Piston and cylinder 45 Assembling the piston and cylinder 47 Cleaning and inspection 45 Dismantling the piston an...

Page 5: ...English 5 Index V Vibration damping system 43 Assembly 43 Cleaning and inspection 43 Dismantling 43 ...

Page 6: ...ion and safety instructions Contents 2 1 General 7 2 2 Security 7 2 3 Target group 7 2 4 Changes 7 2 5 Tools 7 2 6 Structure 7 2 7 Numbering 7 2 8 General instructions 8 2 9 Special instructions 8 2 10 Symbols on the saw 9 2 11 Symbols in the Workshop Manual 9 ...

Page 7: ...l tools are required for some stages All service tools are listed in the Workshop Manual Usage is evident from respective sections Always use Husqvarna s original Spare parts Service tools Accessories 2 6 Structure This Workshop Manual can be used in two diffe rent ways For the repair of a particular system on the chain saw Dismantling and assembly of the entire chain saw Repair of a specific syst...

Page 8: ...he silencer The guide bar chain and clutch cover chain brake must be fitted before the saw is started If not the clutch may come loose and cause injury Poor chain lubrication can result in failure of the chain which could cause serious or fatal injury Take care to ensure that the spring inside the starter assembly does not fly out and cause injury Wear eye protection If the spring is under compres...

Page 9: ...the saw The symbols below are embedded on the chain saw Choke Lever Refuelling Stop button Screw for adjusting chain lubri cation Filling with chain oil 2 11 Symbols in the Workshop Manual This symbol warns of personal injury when the instructions are not followed ...

Page 10: ...ystem Air gap Carburettor type mm inches mm inches CS 2245 0 5 0 02 Walbro MBU 16 0 3 0 012 Zama EL37 C1M CS 2250 0 5 0 02 Walbro MBU 16 0 3 0 012 Zama EL37 C1M Effective cutting length Chain speed at Chain pitch Drive link cm inches max power revs mm inches mm inches m s r min CS 2245 31 50 13 20 17 3 9 000 8 25 0 325 1 3 0 050 1 5 0 058 CS 2250 31 50 13 20 17 3 9 000 8 25 0 325 1 3 0 050 1 5 0 0...

Page 11: ... RCJ 7Y Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump Litres US pints 8 500 rpm Litres US pints ml min CS 2245 0 45 0 95 9 0 26 0 55 Yes CS 2250 0 45 0 95 9 0 26 0 55 Yes Weight without Weight with bar and chain bar and chain kg lbs kg lbs CS 2245 4 9 10 8 6 2 13 6 CS 2250 5 1 11 2 6 2 13 6 rpm GAS OIL Technical data ...

Page 12: ...12 English 4 Special tools Special tools 11 4 6 9 1 2 3 7 8 10 M5 M6 5 M5 ...

Page 13: ...auge Pressurisation during testing 531 03 06 23 10 Test spark plug Checking the ignition module 501 97 64 01 11 Rev counter Adjusting carburettor 502 71 14 01 12 Assembly pliers Fitting spark plug guard 502 50 06 01 13a Cover plate exhaust Sealing the exhaust port 502 54 11 02 13b Cover plates inlet Sealing the intake manifold 501 32 35 01 14 Assembly tool Assembling spring chain brake 502 50 67 0...

Page 14: ...14 English 5 Service data Service data 1 5Nm 1 5Nm 1 5Nm 20Nm 19mm 14Nm 4mm 13Nm 13mm 13Nm 5mm 5 5Nm 4mm 20Nm 2Nm 4mm ...

Page 15: ...English 15 Service data 2 5Nm 4mm 1 5Nm 3 5Nm 5mm 3 5Nm 5mm 3 5Nm 4mm 3 5Nm 4mm 3Nm 3 5Nm 4mm 8Nm 4mm 3 5Nm 4mm 7Nm 4mm 3 5Nm 4mm 5Nm 4mm 3Nm 4mm 23Nm 13mm 1 5Nm ...

Page 16: ...tling the muffler 19 6 4 Assembling the muffler 19 6 5 Replacing the chain catcher 20 6 6 Dismantling the stop control 20 6 7 Resistance measurement stop function 21 6 8 Assembling the choke stop control 21 6 9 Dismantling the throttle lock throttle control and spring 22 6 10 Assembling the throttle lock throttle control and spring 23 ...

Page 17: ...heck all parts Parts must be replaced if cracked or show signs of other defects Always use original spare parts Measure the thickness of the chain brake band It must not be less than 0 6 mm at any point see figure 5 Lubricate the knee joint with grease 4 Hold one hand over the brake spring press a nar row screwdriver in between the rear section of the spring and the clutch cover Carefully pry upwa...

Page 18: ...tch cover in a vice Compress the spring with special tool 502 50 67 01 and push it down with your thumb see figure 7 3 Fit the cover over the chain brake spring tighten ing the screws to a torque of 1 1 5 Nm see figure 8 WARNING Make sure the spring does not fly out and cause injury Wear eye protection 4 Tension the brake spring by using the kickback guard from the saw as a tool Engage it with the...

Page 19: ...ted with a spark arrestor mesh A this must also be removed see figure 11 Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones The spark arrestor mesh is best cleaned with a wire brush If the mesh is damaged it must be replaced If the mesh is blocked the saw will overheat and this will cause damage to cylinder...

Page 20: ...her in position see figure 12 Safety equipment 6 6 Dismantling the choke stop control 1 Remove the cylinder cover and air filter 2 Loosen the screws A see figure 13 3 Loosen the filter holder from the rubber mountings B see figure 13 4 Cut off the starlock washer and pull out the control from the shaft on the filter holder see figure 14 Cleaning and inspection Clean and inspect all parts carefully...

Page 21: ...n A position to give the correct reading see figure 15 The resistance must not be higher than 0 5 Ω when the switch is in the on position The stop switch is in the on position when the button is held down A see figure 15 and in the off position the button is neutral B See figure 16 6 8 Assembling the choke stop control 1 Fit a new control and new starlock washer 2 Secure the carburettor assembly i...

Page 22: ...d with the help of a screwdriver or the like Then dismantle from the shaft in the handle see figure 20 6 Dismantle throttle cable and throttle control 6 9 Throttle lock throttle trigger and return spring removal 1 Loosen the throttle cable on the carburettor the fuel hose and suction hose to the fuel pump 2 Dismantle the tank unit from the engine unit by loosening the screws A and E see figure 17 ...

Page 23: ...it the throttle control pin E with the help of a punch see figure 23 6 Fit the throttle lock D by pressing it onto the shaft in the handle see figure 25 Safety equipment A D C B E D 7 Now loosen the spring Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the dama ged parts with new ones Always use original parts Check that the spring is...

Page 24: ...Dismantling the oil pump and screen 31 7 12 Assembling the oil pump and screen 32 7 13 Dismantling the intake system 32 7 14 Assembling the intake system 32 7 15 Carburettor 33 7 16 Tank unit 42 7 17 Venting the fuel tank 42 7 18 Vibration damping system 43 7 19 Replacing the fuel filter 44 7 20 Changing the fuel hose 44 7 21 Replacing the air purge 44 7 22 Dismantling the piston and cylinder 45 7...

Page 25: ...t from the centre of the pulley and lift off the pulley see figure 3 Cleaning and inspection Clean the parts and check the following The starter cord That the pawls on the flywheel are undama ged i e that they spring back towards the centre and move freely Lubricate the return spring with light oil 7 Repair instructions 2 Pull out about 30 cm of the cord and fasten it in the notch in the pulley ri...

Page 26: ...the cord with the handle Remove the thumb and released back the cord see figure 5 3 Fit a new cord through the hole in the pulley and tie a knot to secure it Feed the other end of the cord through the hole in the starter housing and through the starter handle then tie a double knot in the end Wind about 3 turns of the starter cord onto the pulley Fit the bolt through the centre of the pulley and t...

Page 27: ... recoil spring see Tensioning the recoil spring 7 5 Starter assembly refitting 1 Position the starter assembly on the crankcase and tighten the bolts to a torque of 2 5 3 5 Nm 7 6 Ignition module testing If there is a fault in the ignition system the ignition module must be tested before the ignition system is removed Test the ignition module as follows Connect a test spark plug 502 71 13 01 to th...

Page 28: ...e punch and the flywheel see figure 10 Cleaning and inspection Clean all parts especially the tapers on the flywheel and shaft Check that the flywheel is not cracked or da maged in any other way 2 If replacing the ignition module B loosen the cable lug C and screw A and unscrew it The ignition module can be left in place if you are simply removing the flywheel see figure 9 3 Loosen the flywheel nu...

Page 29: ...ic feeler gauge 502 51 34 02 held in position at the same time without tightening the bolts Fit the earth cable black A Set a distance of 0 3 0 1 mm between the ignition module and magnet The measurement applies to the two lowest lugs on the ignition module Tighten the screws tightening torque 4 5 6 Nm Fit the blue cable on the ignition module see figure 12 3 Then refit cable guide and press the l...

Page 30: ...he clutch shoes by using vernier callipers to measure the diameter of the clutch If the diameter is less than 65 mm the clutch assembly must be replaced see figure 16 3 Unbolt the clutch using tool 502 54 16 03 B and a suitable socket or wrench Turn the clutch clock wise to remove it see figure 15 C Min 65mm 7 9 Centrifugal clutch removal 1 Remove the cylinder cover Disengage the chain brake by pu...

Page 31: ...Undo the bar nut and remove the clutch cover bar and chain Loosen spark plug cap and remove the spark plug fit the piston stop 502 54 15 01 Loosen the clutch clockwise using tool 502 54 16 03 and a suitable socket wrench or combination spanner 2 Remove the centrifugal clutch A Remove the clutch drum B needle bearing C and pump drive wheel D see figure 17 3 Unscrew the chain guide plate see figure ...

Page 32: ...em comprises intake manifold A insulating plate B air flange C carburettor flange D see figure 21 1 Loosen the throttle cable from the bracket on the carburettor flange 2 Now loosen the screws using tool 502 50 87 01 7 14 Assembling the intake system 1 Assemble the carburettor flange and air flange on the intake bellows Now assemble the intake bellows and the partition on the cylinder using tool 5...

Page 33: ...enturi B The pump unit C In the pump unit C fuel is pumped from the fuel tank to the metering unit One side of the pump di aphragm is connected to the crankcase and pulses in time with the pressure changes in the crankcase The other side of the diaphragm pumps the fuel see figure 24 The jets and the fuel s control functions are located in the metering unit A Here the correct quantity of fuel is ad...

Page 34: ...he throttle valve I and J is closed and the choke valve H is open Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied th rough the diffuser jet D see figure 26 F E I H G D J J I D H E I H D F E G D H I J In the part throttle mode see figure below the th rottle valve I is partially open and the choke valve H is open Fuel is supplied through the diffuser...

Page 35: ...he air filter 2 Loosen the bolts A 3 Loosen the filter holder from the rubber moun tings B see figure 29 4 Loosen the suction hose C and return hose G from the fuel pump 5 Dismantle the air shutter D 6 Dismantle the throttle cable E 7 Loosen the fuel hose F see figure 30 Fig 30 Fig 29 D E F C G C ...

Page 36: ...ft out the jet valve E with lever D shaft G and spring H 10 Dismantle the cover K on the pump unit and carefully remove the gasket L and di aphragms M 11 Use a needle or the like and carefully remove the fuel screen J 12 Dismantle the high N and low jet screws P 13 If necessary remove the throttle and choke val ves also dismantle the shafts with lever arms and springs see figure 31 Fig 31 ...

Page 37: ...aphragms are undamaged 2 That there is no play on the throttle and choke valve shafts 3 That the needle valve D and its lever E are not worn see figure 31 4 That the fuel screen J is whole and clean see figure 31 5 That the tips of the high N and low jet screws P are not damaged see figure 31 6 That the intake manifold is undamaged 7 The carburettor has an extra air shutter con nected in parallel ...

Page 38: ...ndle of a small screwdriver see figure 33 4 Fit the pump diaphragm M gasket L and cover K on the pump unit see figure 33 J M L K 5 Fit the needle valve E with lever D pin and spring and tighten the screw F Fit welch plug Q see figure 34 6 Check using a ruler or the like that the lever is level with the assembly plane on the cover The lever arm can be bent if necessary see figure 35 7 Fit the contr...

Page 39: ... out after the carburettor has been repaired but it can also be carried out as trouble shooting before dismantling the carburettor See figure and carry out the test as follows 1 Set the high and low jet screws two turns from the bottom 2 Connect pressure tester to the carburettor s fuel intake 3 Lower the carburettor into a beaker of water see figure 37 4 Pump the pressure up to 50 kPa 0 5 bar 5 N...

Page 40: ...ition the carburettor 4 Fit the return hose G on the fuel pump 5 Fit the throttle cable E see figure 40 6 Assemble the filter holder in the rubber moun tings B 7 Snap the purge into the filter holder 8 Secure the screws A see figure 41 9 Assemble the air filter and cylinder cover Repair instructions Fig 41 Fig 40 D E F C G C ...

Page 41: ...than that it remains 0 2 inches to the bar see figure 42 Replacement of the H needle or complete car burettor 1 Carefully screw the new H needle to the bot tom and turn it anticlockwise A turns CS 2245 A 2 CS 2250 A 2 2 Start the engine If necessary adjust the idling speed with the T screw until the chain stops 3 Adjust the H needle to give a top speed of B rpm Use a tachometer CS 2245 B 12500 13 ...

Page 42: ...nting the fuel tank The two way valve C has the following properties see figure 46 Controlled opening pressure in both directions which prevents a positive pressure or a vacuum developing in the fuel tank and impairing engine performance This also prevents fuel leakage Opening pressure outward 100 450 mbar Opening pressure inward vacuum max 70 mbar 2 positions Test Opening pressure outward 1 Open ...

Page 43: ... Repair instructions 7 18 Vibration damping system Dismantling 1 Dismantle the following parts Bar and chain See the Operator s Manual Cylinder cover See the Operator s Manual Tank unit and handle 2 Dismantle the spring on the cylinder with the help of a 4 mm allen key see figure 48 3 Dismantle the springs on the tank unit with the help of a 4 mm allen key tool 502 50 87 01 see figure 49 Cleaning ...

Page 44: ...ng the air purge Dismantling 1 Dismantle the cylinder cover and the air filter 2 Loosen the screws A see figure 29 3 Loosen the filter holder from the rubber moun tings B see figure 29 4 Loosen the suction hose C and return hose from the fuel pump see figure 30 Assembling 1 Fit the return hose on the fuel pump 2 Assemble the filter holder in the rubber moun tings B see figure 41 3 Snap the purge i...

Page 45: ... 4 Remove the circlips from the ends of the gudgeon pin and press it out Then lift off the piston see figure 52 and 53 5 Remove the bearing from the little end of the con necting rod see figure 53 If replacing the cylinder Remove the intake manifold see Air intake sys tem removal Cleaning and inspection Clean all the components scraping off all traces of old gasket and carbon from the following pl...

Page 46: ...score marks Small scratches can be polished out with fine emery paper The piston ring is freely moving in its groove see figure 55 Measure piston ring wear This should not exceed 1 mm see figure 56 Use the piston to push the piston ring for correct alignment The needle roller bearing is undamaged The intake manifold is undamaged That the air hoses and impulse hose are unda maged Pressure test the ...

Page 47: ...the connecting rod see figure 58 2 Fit the piston with the arrow pointing towards the exhaust port Push the gudgeon pin in and fit the circlips NOTE Use new wire fuses see figure 59 If replacing the cylinder fit the decompression valve tightening to a torque of 12 14 Nm 3 Fit the intake manifold on the cylinder with insula ting plate 4 screws 4 Lubricate the piston ring and piston with two stroke ...

Page 48: ...air mixture from the carburettor to the cylinder 2 The upper intake leads air to the cylinder Assembling the intake system 1 Assemble the carburettor flange D and air flange C on the intake bellows A Now assemble the intake bellows and the partition B on the cylinder using tool 502 50 87 01 see figure 60 Fig 60 A B C D ...

Page 49: ...er and press the rubber sheet 502 54 11 02 between the muffler and cylinder Tighten the top two muffler screws 4 Fit the pressure testing spark plug 503 84 40 02 and connect the pressure testing tool 531 03 06 23 see figure 63 5 Pump the pressure up to 80 kPa 0 8 bar Wait 30 seconds The pressure should not be less than 60 kPa 0 6 bar Remove the cover plates from the silencer and carburettor tighte...

Page 50: ...guard piston and cylinder See special instructions 2 Lift the crankshaft completely out of the crankcase see figure 64 1 Pull the crankshaft bearing off of the crankshaft using a bearing puller see figure 65 2 Place a new bearing on the shaft and push into position using tool 502 50 30 18 see figure 66 7 26 Crankshaft bearings replacement Remove The crankshaft complete from the crankcase Fig 64 Fi...

Page 51: ...er chain and bar See special instructions 7 28 Repairing damaged threads A repair kit 503 27 33 01 is available for repairing damaged threads First drill out the hole using 6 1 mm drill bit for plastic crankcase Then screw in the thread insert using a suitable bolt and spanner This type of thread insert is best suited for use in plastic and magnesium but not for repairing threads in aluminium In t...

Page 52: ...d out through the bolt hole in the crankcase see figure 69 5 Pull the steel wire so the bolt comes out of its hole see figure 69 6 Check that the bolt s square head fits in the washer D which is positioned in the cut out in the crankcase 7 Pull out the bar bolt with its nut Place a spacer between the nut and crankcase see figure 69 8 Refill with chain oil Replacing the rear bar guide 1 Pull out th...

Page 53: ...English 53 Troubleshooting 8 Troubleshooting Contents 8 1 Troubleshooting 54 8 2 Troubleshooting methods 55 ...

Page 54: ...rn throttle valve pivot Loose throttle valve screw Worn throttle valve Needle valve assembly sticking Leak in metering system air or fuel Metering system centre knob is worn Hole in diaphragm Leaking control diaphragm cover plate Crankcase leaking Fuel line blocked Needle valve set too high Needle valve assembly sticking Leak in metering system air or fuel Leaking control diaphragm cover plate Fau...

Page 55: ...compression valve Pressure testing the cylinder High rpm Will not run at full throttle Low power Will not four stroke Adjust H screw Blocked air filter Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor moun...

Page 56: ...510 09 69 26 2008W19 ...

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