Husqvarna Service Manual

Husqvarna Chain Saws
Workshop Manual
101 88 55-26
MODELS
This workshop manual applies to the engine assembly in the following saws:
36/41
281XP/288XP
40/45 394XP
51/55 3120XP
42/242XP/246 268K/272K
254XP/257/262XP
61/268/272XP
272S
English
LIST OF CONTENTS
Introduction ..................................... 3 Safety regulations ........................... 5 Technical 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
2 English
INTRODUCTION
General
This workshop manual provides a detailed description 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:
Updates
As production continues, changes will be introduced 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 problems, the manual should always be read together with all service announcements that apply to the specific model of chain saw.
36 40 41 42 45 51 55 61 242XP 246 254XP
257 262XP 268 272XP 268K 272K 272S 281XP 288XP 394XP 3120XP
Tools
For specific procedures special tools are required. In this workshop manual, all the service tools required are listed. Use of the tools is described in appropriate sections. Always use Husqvarna original: Spare parts Service tools Accessories
Layout 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. 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. 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.
Target group
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 understood 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.
English
INTRODUCTION
Use
This workshop manual can be used in two different ways: Repair of a specific sub-assembly Dismantling and reassembly of the entire chain saw Dismantling and reassembly of the entire chain saw When the entire chain saw is to be dismantled and reassembled, proceed as follows: 1. Refer to page 57, which deals with the Starter and carry out the instructions under the heading Dismantling. Work forwards through the manual and carry out Dismantling instructions in the order that the sections occur. Return to the Starter on page 58 and follow the instructions under Cleaning and Inspection. Work forward through the manual and carry out Cleaning and Inspection in the order that the sections occur. Order or collect all the required spare parts from the spare parts stores. In order to Assemble the chain saw, proceed as follows: Refer to pages 117-120 which deals with the Crankcase and carry out the instructions 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.
Repair of a specific sub-assembly When a specific sub-assembly on the chain saw is to be repaired, proceed as follows: 1. Refer to the page referring to the relevant subassembly. Carry out the steps: Dismantling Cleaning and inspection Reassembly 2.
3.
2.
4.
5.
6.
Continue to work backwards through the manual and carry out Assembly instructions as the sections occur. In order to improve understanding, some sections begin with a Description of the relevant sub-assembly.
4 English
SAFETY REGULATIONS
General Instructions
Workshops where chain saws are serviced must be equipped with safety equipment as set out in local directives. No one should repair a chain saw without first having read and understood the contents of this workshop manual. The following warning texts are to be found in this manual in certain places. The warning texts occur before the procedure to which they refer.
Special instructions
The fuel used in the chain saw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause eye and skin irritation. 3. Can cause breathing difficulties 4. Is highly inflammable. The bar, chain and clutch cover (chain brake) must be assembled before the chain saw is started, otherwise the clutch may come loose causing personal injury. Wear ear muffs when testing the chain saw.
WARNING! The warning text indicates a risk of personal injury if instructions are not followed.
Do not use the saw until it has been adjusted so that the chain does not rotate when idling. Bear in mind the fire risk. The saw can produce sparks that can cause a fire hazard..
NOTE! The warning text indicates a risk of damage to equipment if instructions are not followed.
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.
The chain saw is type approved with regard to safety according to applicable legal requirements when fitted with the cutting equipment specified in the Operator's Manual. Equipping the saw with other equipment or accessories and spare parts not approved by Husqvarna can result in non compliance with these safety requirements and liability for persons carrying out such modifications.
Inadequate chain lubrication can result in the chain breaking, which can cause serious or fatal injury. Make sure that the starter recoil spring does not fly out and cause personal injury. Release the spring tension before the cord pulley is removed. When removing the pressure spring for the chain brake, ensure that the brake is in the 'on' position which reduces the spring tension, otherwise the spring can fly out causing personal injury. After repair, the chain brake must be checked in accordance with the instructions on page 47. When replacing the crankshaft bearings note that the crankcase halves are hot. Use protective gloves. 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.
English
TECHNICAL DATA
Displacement cm3 36 40 41 42 45 51 36 40 40 42 44 51
Bore mm 38.0 40.0 40.0 42.0 42.0 45.0
Stroke mm 32.0 32.0 32.0 30.0 32.0 32.0
Max. power at r/min 9000 9000 9000 9300 9000 9000
Spark plug gap mm/inches 36 40 41 42 45 51 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02
Ignition system PHELON PHELON PHELON SEM AM 7 PHELON ELECTROLUX ET
Air gap mm/inches 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012
Carburettor WALBRO WT 239 ZAMA C1Q-EL1 WALBRO WT 239 WALBRO HDA 98 ZAMA C1Q-EL1 WALBRO WT 170
Bar length cm/inches 36 40 41 42 45 51 33-46/13-18 33-46/13-18 33-46/13-18 28-46/11-18 33-46/13-18 33-51/13-20
Chain speed m/s 17.3/9000 rpm 17.4/8500 rpm 17.3/9000 rpm 17.9/9300 rpm 17.4/8500 rpm 17.4/9000 rpm
Chain pitch inches .325-3/8 .325 .325-3/8 .325 .325 .325-3/8

1)
Drive link gauge mm/inches 1.3/ .050 1.3/ .050 1.3/ .050 1.5/ .058 / 1.3/ .0501) 1.3/ .050 1.5/ .058 / 1.3/ .0501) From May 1996
6 English
TECHNICAL DATA
Idling speed r/min 36 40 41 42 45 51 3000 2500 3000 2700 2500 2500
Engagement speed r/min 4500 3600 4500 3800 3600 3700
Max. speed r/min 13000 12500 13000 14500 12500 12500
Spark plug Champion RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y
Fuel tank volume Litres 36 40 41 42 45 51 0.4 0.5 0.4 0.5 0.5 0.6
Oil pump capacity cm /min at 8.500 rpm

3
Oil tank volume Litres 0.2 0.25 0.2 0.27 0.25 0.3
Automatic oil pump
7 8 7 3-7 8 10
Yes Yes Yes Yes Yes Yes
Weight without bar and chain kg 36 40 41 42 45 51 4.6 4.7 4.6 4.7 4.7 5.2
Weight with bar and chain kg/lbs 5.3 (13") 5.4 (13") 5.3 (13") 5.5 (13") 5.4 (13") 6.2 (15")
Handle heater Watt/ r/min No No No No No No
English
TECHNICAL DATA
Displacement cm3 55 61 242XP 246 254XP 257 53 62 42 46 54 57
Bore mm 46.0 48.0 42.0 44.0 45.0 46.0
Stroke mm 32.0 34.0 30.0 30.0 34.0 34.0
Max. power at r/min 9000 8300 9900 9000 9300 9000
Spark plug gap mm/inches 55 61 242XP 246 254XP 257 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02
Ignition system ELECTROLUX ET ELECTROLUX ET SEM AM 7 SEM AM 7 ELECTROLUX ET ELECTROLUX ET
Air gap mm/inches 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012
Carburettor WALBRO WT 170 TILLOTSON HS 254 WALBRO HDA 98 WALBRO HDA 98 WALBRO HDA 35B WALBRO HDA 120
Bar length cm/inches 55 61 242XP 246 254XP 257 38-51/15-20 38-51/15-20 28-46/11-18 28-46/11-18 33-51/13-20 33-51/13-20
Chain speed m/s 17.4/9000 rpm 18.4/8300 rpm 19.1/9900 rpm 17.3/9000 rpm 17.3/9300 rpm 17.3/9000 rpm
Chain pitch inches .325-3/8 3/8 .325 .325 .325-3/8 .325-3/8

1)
Drive link gauge mm/inches 1.5/ .058 / 1.3/ .050 1) 1.5/ .058 1.5/ .058 / 1.3/ .050 1) 1.5/ .058 / 1.3/ .050 1) 1.5/ .058 1.5/ .058 From May 1996
8 English
TECHNICAL DATA
Idling speed r/min 55 61 242XP 246 254XP 257 2500 2500 2700 2700 2700 2700
Max. speed r/min 12500 12000 15500 15000 13800 13500
Fuel tank volume Litres 55 61 242XP 246 254XP 257 0.6 0.75 0.5 0.5 0.6 0.6
Oil pump capacity cm3/min at 8.500 rpm 10 4/8/12/17 3-7 3-7 3-10 3-10
Oil tank volume Litres 0.3 0.45 0.27 0.27 0.3 0.3
Automatic oil pump
Yes Yes Yes Yes Yes Yes
Weight without bar and chain kg 55 61 242XP 246 254XP 257 5.2 6.1 4.7 4.7 5.4 5.6
Weight with bar and chain kg/lbs 6.2 (15") 7.1 (15") 5.5 (13") 5.5 (13") 6.3 (13") 6.6 (13")
Handle heater Watt/ r/min No No 65/10.000 No 65/10000 65/10000
English
TECHNICAL DATA
Displacemennt cm3 262XP 268 272XP 268K 272K 272S 62 67 72 67 72 72
Bore mm 48.0 50.0 52.0 50.0 52.0 52.0
Stroke mm 34.0 34.0 34.0 34.0 34.0 34.0
Max. power at r/min 9600 9000 9300 9000 9300 9300
Spark plug gap mm/inches 262XP 268 272XP 268K 272K 272S 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02
Ignition system ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET
Air gap mm/inches 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012
Carburettor WALBRO HDA 120 TILLOTSON HS 260 TILLOTSON HS 260 TILLOTSON HS 255 TILLOTSON HS 255 TILLOTSON HS 255
Bar length cm/inches 262XP 268 272XP 268K 272K 272S 33-51/13-20 38-51/15-20 38-51/15-20 -
Chain speed m/s 18.5/9600 rpm 18.4/9000 rpm 20.0/9300 rpm -
Chain pitch inches .325-3/8 3/8 3/8 -
Drive link gauge mm/inches 1.5/ .058 1.5/ .058 1.5/ .058 -
10 English
TECHNICAL DATA
Idling speed r/min 262XP 268 272XP 268K 272K 272S 2700 2500 2500 2500 2500 2500
Max. speed r/min 13500 12500 13500 10000 10000 10000
Fuel tank volume Litres 262XP 268 272XP 268K 272K 272S 0.6 0.75 0.75 0.75 0.75 0.75
Oil pump capacity cm3/min at 8.500 rpm 6.5-13.5 4/9/13/17 5/9/14/19 -
Oil tank volume Litres 0.3 0.45 0.45 -
Automatic oil pump
Yes Yes Yes -
Weight without chain and bar kg 262XP 268 272XP 268K 272K 272S 5.8 6.2 6.3
Weight with chain and bar kg/lbs 6.8 (13") 7.2 (15") 7.3 (15") -
Handle heater Watt/ r/min 65/10000 65/10000 65/10000 -
9.5 9.6 21.0 (including carriage)
English
11
TECHNICAL DATA
Displacement cm3 281XP 288XP 394XP 3120XP 81 87 94 119
Bore mm 52.0 54.0 56.0 60.0
Stroke mm 38.0 38.0 38.0 42.0
Max. power at r/min 9000 9300 8800 9000
Spark plug gap mm/inches 281XP 288XP 394XP 3120XP 0.5/ .02 0.5/ .02 0.5/ .02 0.5/ .02
Ignition system SEM AM 7 SEM AM 7 SEM AM 44 SEM AM 37
Air gap mm/inches 0.3/ .012 0.3/ .012 0.3/ .012 0.3/ .012
Carburettor TILLOTSON HS 228 TILLOTSON HS 228 WALBRO WJ 39 WALBRO WG 6
Bar length cm/inches 281XP 288XP 394XP 3120XP 38-71/15-28 38-71/15-28 46-91/18-36 60-107/24-42
Chain speed m/s 20.0/9000 rpm 20.7/9300 rpm 19.6/8800 rpm 20.1/9000 rpm
Chain pitch inches 3/8 3/8 3/8-.404 .404
Drive link gauge mm/inches 1.5/ .058 1.5/ .058 1.5/ .058 - 1.6/.063 1.6/ .063
12 English
TECHNICAL DATA
Idling speed r/min 281XP 288XP 394XP 3120XP 2500 2500 2500 2500
Engagement speed r/min 3200 3200 3400 3300
Max. speed r/min 12500 12500 12500 11500-12500
Spark plug Champion RCJ 6 Y RCJ 6 Y RCJ 6 Y RCJ 7 Y
Fuel tank volume Litres 281XP 288XP 394XP 3120XP 0.9 0.9 0.9 1.25
Oil pump capacity cm3/min at 8.500 rpm 9/12/15/18 9/12/15/18 14-21 8-51
Oil tank volume Litres 0.5 0.5 0.5 0.7
Automatic oil pump
Yes Yes Yes Yes
Weight without bar and chain kg 281XP 288XP 394XP 3120XP 7.5 7.5 7.9 10.4
Weight with bar chain kg/lbs 8.7 (18") 8.7 (18") 9.2 (18") 12.3 (28")
Handle heater Watt/ r/min 56/7200 56/7200 65/10000 No
English
13
TOOLS
Tools for all chain saws
502 50 57-01 3/16" 502 50 16-01 6 mm 502 50 64-01 5 mm 502 50 18-01 4 mm 502 50 19-01 3 mm
502 50 22-01 8 mm 502 50 23-01 10 mm
502 50 88-01 5 mm 502 50 87-01 4 mm 502 50 86-01 3 mm
502 71 13-01 504 98 26-01 (36, 41, 40, 45)
502 50 06-01
502 51 34-02 (0,3 mm) 502 51 91-01 (0,5 mm) 502 50 83-01 502 50 37-01
502 70 09-01 compl 502 50 70-01
502 51 02-01
502 71 14-01
14 English
TOOLS
Tools for saws 36 and 41
3 mm; 4 mm; 5 mm 8 mm; 10 mm
Tools for saws 40, 45, 51 and 55

4 mm 8 mm
502 50 33-01 505 26 79-12 40 > 910 1116 45 > 925 1168 50 > 925 0856
502 50 33-01
502 51 94-01
502 51 94-01
530 03 11-12
530 03 11-36
502 50 99-01 (55)
502 50 26-01 (55)
505 38 18-17 (40. 45)
502 51 00-02 502 51 61-01 (51, 55) 504 90 90-01
502 50 30-09 40 > 910 1116 45 > 925 1168
502 50 79-01 (55)
compl 502 50 38-01 502 54 03-01 (40, 45, 55)
504 90 29-02
502 50 46-01 (55)
English
15
TOOLS
Tools for saws 42, 242 and 246
3 mm; 4 mm 8 mm

3 mm; 4 mm 8 mm
502 50 33-01 *compl 502 51 49-02
502 50 33-01
*compl 502 51 49-02 502 51 49-01* *502 51 54-01
502 51 49-01* *502 51 54-01
502 50 26-01* 502 70 03-01
502 50 99-01
502 50 26-01* 502 50 99-01
compl 502 50 31-01
502 51 61-01
504 90 90-01 502 51 61-01 504 90 90-01
502 50 82-01 502 50 30-07
502 51 32-01
502 51 50-01 502 50 79-01 502 50 30-10
502 51 00-02 compl 502 50 38-01 502 50 45-01 502 50 72-01 compl 502 50 38-01 502 50 45-01
502 50 72-01
502 50 71-01
502 50 46-01
502 50 71-01
502 50 46-01
16 English
TOOLS
3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm)

3 mm; 4 mm; 3/16" 8 mm 502 71 36-01 (4 mm)
502 50 33-01 *compl 502 51 49-02 *compl 502 51 49-02
502 50 33-01
502 51 49-01* *502 51 54-01
502 51 49-01* *502 51 54-01
502 50 26-01* 502 70 03-01
502 50 26-01*
compl 502 50 31-01
502 51 61-01
504 90 90-01
502 51 61-01
504 90 90-01
502 51 69-01 (268)
502 50 82-01 502 50 30-04 502 50 30-08
502 50 53-01 502 50 66-02 502 50 67-01 502 51 00-02
502 50 52-01
502 50 66-02 compl 502 50 38-01
compl 502 50 38-01 502 50 45-01
502 50 47-01
502 50 47-01 502 50 46-01
502 50 48-01
502 50 46-01
502 50 81-01
502 50 20-01
English
17
TOOLS
3 mm; 4 mm; 5 mm; 3/16" 8 mm; 10 mm
502 50 33-01
*compl 502 51 49-02
502 51 49-01* *502 51 54-01
502 50 26-01*
504 90 90-01
502 50 82-01
502 50 52-01 502 50 30-08
502 50 66-02 compl 502 50 38-01
502 52 01-01 (394) 502 71 38-01 (3120)
502 52 04-01 (394) 502 71 40-01 (3120)
502 71 39-01 (394)
18 English
TOOLS
List of tools
Order number 502 50 06-01 502 50 16-01 502 50 18-01 502 50 19-01 502 50 20-01 502 50 22-01 502 50 23-01 502 50 26-01 502 50 30-04 502 50 30-08 502 50 30-09 502 50 30-10 502 50 31-01 502 50 33-01 502 50 37-01 502 50 38-01 502 50 45-01 502 50 46-01 502 50 47-01 502 50 48-01 502 50 52-01 502 50 57-01 502 50 64-01 502 50 66-02 502 50 67-01 502 50 70-01 502 50 71-01 502 50 72-01 502 50 79-01 502 50 81-01 502 50 82-01 502 50 83-01 502 50 86-01 502 50 87-01 502 50 88-01 502 50 99-01 502 51 00-02 502 51 02-01 502 51 32-01 502 51 34-02 Designation Pliers Allen key Allen key Allen key Assembly tool Socket Socket Puller Assembly tool Assembly tool Assembly tool Assembly tool Puller Piston stop Vacuum gauge Pressure gauge Extended socket Extended socket Cover plate Cover plate Assembly socket Allen key Allen key U-key U-key Assembly tool, piston Cover plate Cover plate Assembly mandrel Cover plate Assembly mandrel Hook, tank valve Allen key Allen key Allen key Puller sleeve U-key Assembly fixture Assembly sleeve Feeler gauge Order number 502 51 49-01 502 51 49-02 502 51 50-01 502 51 54-01 502 51 61-01 502 51 69-01 502 51 69-01 502 51 94-01 502 52 01-01 502 52 04-01 502 54 03-01 502 70 09-01 502 71 13-01 502 71 14-01 502 71 36-01 502 71 38-01 502 71 39-01 502 71 40-01 504 90 29-02 504 90 90-01 504 98 26-01 505 26 79-12 505 38 18-17 Designation Puller Puller Socket Bolt set Dismantling tool, crankcase Assembly mandrel Feeler gauges Assembly mandrel Cover plate Spacer Spacer Pump blower Test spark plug Tachometer Allen key Cover plate Cover plate Spacer Cover plate Puller Silicone rubber Assembly mandrel Puller
English
19
SERVICE DATA Saws 36 and 41
15
10
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).
20 English
SERVICE DATA
15
28 3
English
21
SERVICE DATA
Saws 42, 242 and 246
5 8-10
7-8
242
4-5
15 10 5
42 246
242
42 246
Character key
22 English
SERVICE DATA
9 13
20
2 2
4 28 6 9
2
English
23
SERVICE DATA
Saws 40 and 45
3-4
2-3 7-8 25-35 2-3
2-3
Character key
2-3
10-12
24 English
SERVICE DATA
2-3
3-4
2-3
2-3
20
2-3
2-3
8-10
2-3
2-3
3-4
2-3
25-30
2-3
English
25
SERVICE DATA
Saws 51 and 55
4-5
7-8
15
30-40 6-8
3-4 3-4
8-10
1,5-2
Character key
= Lubricate using two-stroke oil. = Lubricate using saw chain oil. = Lubricate using grease. = Locking fluid (Loctite).
3-4
Numbers by components that are bolted refer to the tightening torque in Nm.
26 English
SERVICE DATA
3-4
3-4
3-4 15 8-10 12-14
3-5
1-2
25
3-4
3-4
English
27
SERVICE DATA
Saws 254 and 257
5 5
254
10
257
5 10 15
35
Character key
3 5
28 English
SERVICE DATA
3 4
10 13
20
254
2
4 9 28
English
29
SERVICE DATA
Saw 262
5 4
6 10 15
4 35
Character key
4 4
30 English
SERVICE DATA
2 4
20
13
5 4 4
3 4 9 28
5
English
31
SERVICE DATA
Saws 61, 268 and 272
2 5
10 6 6
15
10 6 35
61
5
35
268 272
1 4 8
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). 3
32 English
SERVICE DATA
3 1 3
61
1 3 1 15 10 3
268 272
14
5 4 6 6 4
272
4
3 28 4 9
English
33
SERVICE DATA
Saws 281 and 288
13 4 6 15
35
Character key
34 English
SERVICE DATA
4
3 6
20 11
17 7 7
7 6 4
35 7 9
English
35
SERVICE DATA
Saw 394
10-12 15 6-8
2-4
7-9
Character key
36 English
SERVICE DATA
5-6
10-12
20-22,5
3-5
12-14
3-5 5-6
4-5
30-40
2-3
English
37
SERVICE DATA
Saw 3120
5 4
12 15
38
5 3
1 8 5 5 7 7
Character key
38 English
SERVICE DATA
3 5 7
17
12
20
5 10
12 5 8
6 3
40 4 9 4
English
39
TROUBLE SHOOTING Trouble shooting schematic

Faults that can develop on the chain saw are divided into four groups as follows. In each category, possible malfunctions are shown on the left, with a list of possible faults on the right. The most probable fault is given first and so on.
Starting
Difficult starting Adjust L-screw Air filter blocked Choke not working correctly Worn choke shaft Worn choke plate Fuel filter blocked Fuel line blocked Piston ring seized Blocked impulse channel Loose or faulty fuel pipe Hole in 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
Idling (low rpm) (cont.)

Idles when L-screw closed Worn needle valve/needle Leaking control diaphragm/ cover plate Control system sticking Worn throttle lever Faulty diffuser jet Fuel filter blocked Fuel line blocked Leaking manifold Loose carburettor mounting Worn throttle valve shaft Loose throttle valve screw Worn throttle valve Control system sticking Leak in throttle system (air or fuel) Control diaphragm centre knob is worn Hole in diaphragm Leaking control diaphragm/ cover plate Crankcase leaking
Idling uneven
Carburettor leaking fuel
Flooding when the engine is not running
Idling (low rpm)

Will not idle Adjust L-screw Leaking manifold (intermediate) Loose carburettor mounting Loose or faulty fuel pipe Fuel filter blocked Fuel line blocked Fuel tank breather blocked Throttle shaft and lever stiff Throttle cable sticking Defective throttle return spring Bent throttle lever shaft stop Faulty diffuser jet
L-screw requires constant adjustment
Fuel line blocked Control system set too high Control system sticking Control system (air or fuel) Leaking control diaphragm/ cover plate Faulty diffuser jet Crankcase leaking Control system set too high Control system sticking Control system damaged Worn needle valve Leaking control diaphragm/ cover plate Control system incorrectly assembled
Too much fuel at idling
Idling too rich
Adjust L-screw Worn needle valve/needle Control system set too high Worn throttle lever Leaking control diaphragm/ cover plate Control system sticking
40 English
TROUBLE SHOOTING
High rpm
Will not run at full throttle Adjust H-screw Blocked air filter Blocked fuel tankbreather 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 manifold Loose carburettor mounting Control system set too low Control system damaged Control system incorrectly assembled Leaking control diaphragm/cover Control system sticking Blocked silencer Adjust H-screw Blocked fuel tankbreather Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Control system sticking Leak in throttle system (air or fuel) Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm/cover Blocked fuel tank breather 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 manifold Loose carburettor mounting bolts Control system set too low Leak in throttle system (air or fuel) Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking control diaphragm/cover
Acceleration and retardation

Does not accelerate Adjust L-screw Adjust H-screw Blocked air filter Blocked fuel tankbreather Blocked fuel filter Fuel line blocked Loose or damaged fuel line Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking manifold Loose carburettor mounting Throttle set too low Control system incorrectly assembled Control system sticking Faulty diffuser jet Blocked silencer Adjust L-screw Adjust H-screw Faulty pump diaphragm Control system set too high Control system sticking Faulty diffuser jet Adjust L-screw Adjust H-screw Blocked air filter Faulty pump diaphragm Faulty diffuser jet
Low power
Motor stalls when throttle released
Over rich acceleration
Trouble shooting methods

In addition to faults given in the above schematic, trouble shooting can be carried out on a specific component or sub-system of the chain saw. The different testing procedures are described in respective sections and are as follows: 1. Pressure testing the carburettor. See page 100. Pressure testing the crankcase and cylinder. See page 114. Pressure testing the decompression valve. See page 114. Checking the operation of the chain brake. See page 47.
Will not four-stroke
2.
3.
4.
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41
SAFETY EQUIPMENT Chain brake

Dismantling
Dismantle the clutch cover and clean. See the operating instructions. A
Slide the hand guard forwards so that the brake is actuated.
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.
All saws except 3120
3120
Remove the cover on the chain brake spring. The cover has 4 or 5 screws.
WARNING! If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in personal injury! Wear protective glasses!
Place the clutch cover in a vice with the jaws positioned as shown below and release the tubular pin B. Carefully knock out the tubular pin B. B
!
42 English
WARNING! If the brake is not 'on', the spring can fly out resulting in personal injury. Wear protective glasses!
Continues on next page.
3120 continues on next page.
SAFETY EQUIPMENT
All saws except 3120 3120
Slide up the back edge of the spring with a screwdriver.
Carefully unscrew the vice so that the pressure rod and the ratchet move out of the clutch cover.
Dismantle the pressure rod from the brake band. Use a punch to knock out the pin holding the knee link.
Remove the screw that holds the fixed end of the band.
36, 41, 61, 268, 272, 281 and 288
40, 42, 45, 51, 242, 246, 55, 254, 257, 262 and 394
Lift up the band's fixed end using a screwdriver and remove the loose parts.
Knock out the band's fixed end using a punch through the hole in the clutch cover and remove the loose parts.
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43
SAFETY EQUIPMENT
Cleaning and Inspection
Clean and inspect all parts. The thickness of the brake band must not be under 0.8 mm at any point.
Min. 0.8 mm
Assembly
Fit the band's fixed end into position on the clutch cover.
All saws except 3120
3120
Grease the knee link and knock in the tubular pin that holds the knee link.
Fit the screw that holds the band's fixed end.
44 English
SAFETY EQUIPMENT
Slide the spring over the knee link's stud and press down the opposite end of the spring into its recess.
Fit the spring and screw onto the pressure rod on the brake band. Note! Plastic sleeve. Bottom the screw onto the pressure rod thread and back off 4-5 turns.
Fit the cover over the spring.
WARNING! If the clutch cover slides out of the vice's grip the spring can fly out with immense force resulting in personal injury!
Grease and fit the ratchet. Set the unit in a vice, positioned in the jaws as shown below.
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45
SAFETY EQUIPMENT
Carefully tighten the vice until the hole for the tubular pin and the ratchet align.
Fit the hand guard, the two bushings and the screw.
Carefully knock in the pin.
Fit the cylindrical pin.
Pull back the hand guard so that the brake is not actuated.
Check the chain brake as described on the next page.
46 English
SAFETY EQUIPMENT
Checking brake operation
WARNING! After repair, the chain brake must be checked as set out in the following instructions.
The engine should not be running during the test. Test that the chain brake comes on as follows:
Hold the chain saw above a firm surface. The distance between the bar and the surface are shown in the table below.
L Bar length, L 15-20 inches 21-28 inches 29-32 inches Height, H 50 cm 70 cm 80 cm H
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.
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47
SAFETY EQUIPMENT Chain catcher

Description
The chain catcher is intented to catch the chain if it should break. The chain catcher has a different design and is secured differently on the chain saws described in this manual. The following designs are used: 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 operating instructions
Check the chain catcher and replace if broken or badly damaged. The tightening torque is stated in the service data
Reassemble the chain and bar. See the operating instructions
48 English
SAFETY EQUIPMENT Muffler

Dismantling
B
WARNING! Do not touch the muffler until it has cooled. Risk of burns!
C If the saw is equipped with muffler mounting (A), unscrew this from the crankcase and muffler. A
Unscrew the muffler from the cylinder (M5 or M6 bolts, M5 or M6 nuts).
Remove the muffler, gasket and cooling plate (B) if the saw is so equipped.
If the saw is equipped with a spark arrester (C), remove this.
Saw 242 Cat
Saws 36 and 41
Dismantle the muffler as shown in the figure to the right.
1
A
WARNING! The coating on and in the catalytic converter element (A) is hazardous to your health if touched. Wear protective gloves when working on a catalytic converter
Dismantle the muffler as shown in the figure to the right.
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49
SAFETY EQUIPMENT
Clean all parts and check the following: That the muffler and muffler mountings are not cracked or otherwise damaged. That the gaskets are OK.
Assembly
Clean all contact surfaces. Saws 36 and 41 Assemble the muffler and fit to the cylinder. Tightening torque, see page 20.
Other saws
If the saw is equipped with a spark arrester (C), fit this.
Fit the cooling plate (B) if fitted, gasket and muffler on the cylinder.
!
242 Cat
Other saws
Only specially treated bolts may be used on the catalytic converter (high temperature). See spare parts catalogue.
Tighten all bolts using the tightening torque set out in the "Service data". B
See "Service data" regarding tightening 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.
D C E A
50 English
SAFETY EQUIPMENT Stop switch

Dismantling
Remove the earth screw (A) and cable (B). A
Press the switch's securing tabs (C) towards each other and push out the switch. B C

Clean 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 more than 1000 ohm.
Assembly
Press the switch into the socket on the tank unit.
Fit the earth screw (A) and cable (B). Note! On some models the earth cable should be connected to the earth screw.
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51
SAFETY EQUIPMENT Throttle lock

Dismantling
Saws 40, 45. Other saws.
WARNING! The fuel used in the chain saw poses the following hazards: 1. The liquid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable.
See continuation on next page. Remove the tank unit from the engine assembly. See page 103.
Dismantle the throttle lock pin (A) using a punch. A
Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP, 288XP and 394.
Saw 3120. See continuation on next page.
Saw 394
Saws 61, 268, 272XP, 272K, 272S, 281XP and 288XP.
Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP, 257 and 262XP.
Turn the throttle lock as shown in the figure, and lift it out with the spring from the cut-out in the handle.
Slide the throttle lock and remove it forwards as shown in the figure.
Carefully prise up the lock from the slot and remove.
52 English
SAFETY EQUIPMENT
Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP, 288XP and 394. Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP, 257 and 262XP.
Dismantle the throttle pin (B) by using a punch. B
Remove the rubber element (A). Slide out the throttle pin (B) and lift out the throttle arm and spring. B A
Saw 3120 Dismantle the throttle. On saw 394, also remove the throttle cable. Remove the three pins with a punch. Saws 40 and 45
Remove the three screws in the side of the handle as well as the screw holding the spring under the handle.
Press the throttle lock down and move it and the trigger forwards until the back edge of the lock appears.
Lift out the throttle lock and the throttle. Lift out the trigger lock.
Lift out the throttle with cable from the front.
Remove the springs where appropriate.
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SAFETY EQUIPMENT
Cleaning and inspection
Clean all parts.
Check that the lock's activation mechanism is not worn. For examples of the activation mechanism, see the figure.
Check that the springs, where fitted, are OK and have the correct tension.
On those saws fitted with a throttle cable, check that the cable and lever are OK and run freely.
54 English
SAFETY EQUIPMENT
Assembly
Saws 36, 40, 41, 45, 42, 242XP, 246, 51, 55, 254XP, 257 and 262XP. Other saws.
Fit springs in appropriate cases.
Saws 36, 41, 42, 242XP, 246, 51, 55, 254XP, 257, 262XP and 394.
Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP and 288XP. See next page.
Saws 40, 45.
Saw 3120.
On saw 394, fit the cable to the trigger. Insert them into the handle from the front.
Fit the cable to the trigger and install the throttle lock and trigger.
Fit the trigger with the cable from the front.
Fit the pin (B) and spring (when used).
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 can be slid in under the edge of the handle.
All saws except 40 and 45 continue on the next page.
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55
SAFETY EQUIPMENT
Saws 36, 41, 42, 242XP, 246, 51, 55, 254XP, 257, 262XP and 394. Saws 61, 268, 268K, 272XP, 272K, 272S, 281XP and 288XP. Saw 3120.
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.
Fit the three pins that hold the cable bracket, throttle lock and trigger.
Fit the throttle lock from the front.
Fit the throttle lock pin.
Fit the tank unit. See page 105.
56 English
STARTER
Dismantling
Dismantle the starter See the operating instructions.
Pull out the cord 20-30 cm andinsert it into the cut-out in the starter pulley rim. Some saws have several long cut-outs.
Rotate the starter pulley anticlockwise until the spring-tension on the starter pulley ceases.
Dismantle the starter pulley's centre bolt and washer.
WARNING! If the spring tension is released when lifting the starter pulley, the spring can fly out and cause personal injury! Wear protective glasses!
Lift out the starter pulley carefully.
If the starter has a cord guide (A), remove this
If the cord is to be replaced, cut it off and pull out the bits from the handle and starter pulley using a pair of long nosed pliers.
WARNING! Ensure that the spring does not fly out and cause personal injury! 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 spring.
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57
STARTER
Clean all parts and check the following: The starter cord. The dogs in the starter pulley. That the pawls on the flywheel are OK, and spring back towards the centre and move freely.
WARNING! Ensure that the spring does not fly out and cause personal injury!
Changing the ferrule

Remove the parts of the old ferrule.
Fit the new ferrule in the starter housing. B A Use a wrench, spacer (A) and ball (B). Splay out the ferrule on the inside as shown in the figure.
58 English
STARTER
Assembly
WARNING! Ensure that the spring does not fly out and cause personal injury!
If a new spring is to be fitted, position in its security/holder so that the eye is over the stud in the starter cover.
Slide 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.
61, 268, 272, 281 and 288.
42, 242, 246, 51, 55, 254, 257,262, 394 and 3120.
Screw the cord to the starter pulley.
Secure the cord on the starter pulley.
Knot the cord on the starter pulley.
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59
STARTER
Grease the return spring and starter pulley bearing.
If the starter unit has a cover plate (B) over the spring, fit the plate.
Fit the starter pulley. Rotate back and forth until the starter pulley catches in the spring.
Fit the starter pulley washer and bolt and tighten the bolt to 4 Nm.
If the starter has a cord guide (A), fit this.
Pull out the cord through the hole in the cover and fit the handle, secure with a double knot.
A 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. Check the cord tension 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 starter on the crankcase. Tighten the bolts to 4 Nm.
60 English
ELECTRICAL SYSTEM Ignition system

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 ignition module is OK.
Dismantling
Remove the cylinder cover and the starter unit.
Remove the spark plug and fit the piston stop.
Saws 36 and 41. Loosen the cable that runs to the stop switch from the ignition module. Release the cables from the guide rail and remove the guide rail.
Loosen the flywheel nut and unscrew it 1 turn Tap the nut quickly with a hammer so that the flywheel comes loose Remove the nut and flywheel.
Other saws, see next page.
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61
ELECTRICAL SYSTEM
All saws except 36 and 41.
Unscrew the two pawls and springs located on the flywheel.
Fit puller 502 51 49-02 and loosen the flywheel. Remove the puller, nut and flywheel.
Loosen the flywheel nut and undo until it aligns with the end of the shaft.
Continuation all saws
Remove the ignition coil.
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.
62 English
ELECTRICAL SYSTEM
Clean all parts, especially the flywheel and shaft taper. Check that the flywheel is not cracked or damaged in any other way.
Assembly
Fit the generator if the saw is fitted with handle heating. Tighten the bolts to 4 Nm and lock using Loctite. Fit the cable to the actual contact on the saw. Adjust the length of the cable by knotting it.
Place the flywheel on the crankshaft. Rotate gently until the flywheel's key mates in the keyway on the shaft
Replace the flywheel washer 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.
Continue assembly on next page.
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63
ELECTRICAL SYSTEM
Insert feeler gauge 502 51 34-02 (0.3 mm) between the ignition module and the flywheel's magnet. Push the ignition module towards the flywheel and tighten the bolts to 4 Nm.
Fit the guide rail, insert the cables and fit the cable to the ignition module.
Saws 42, 242, 246, 281 and 288.
Other saws.
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 cylinder cover.
Fitting the spark plug cover

Make a hole in the HT cable using pliers 502 50 06-01.
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.
Stop switch
The stop switch is described in the section "Safety equipment". See page 51.
64 English
ELECTRICAL SYSTEM Handle heating

Description
Some saws are equipped with an electric handle heating. This consists of the following parts: Generator. Power switch. Heater loop in the tank unit. Handle loop with heater loop. (One or two loops). The above components are connected in series, which means that if there is a fault in one, all components stop working. The wiring diagram is shown in the figure to the right. The order of components can vary from saw to saw.
Trouble shooting
A1 Trouble shooting can take place with most components connected to the saw. An ohm meter is required for trouble shooting. A2
C D
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.
Measurement points: A1 and A2 Earth. E.g. the cylinder A1 - B Measurement of the generator B-C Measurement of the handle loop C-D Measurement of the heater loops in the rear handle D - A2 Measurement of the power switch
Trouble shooting individual components, see next page.
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65
ELECTRICAL SYSTEM
Checking the generator Check the handle loop
Connect the ohm meter to the cylinder (point A1) and point B. The ohm meter should read 0.9-1.3 ohm. Replace a generator that has higher or lower values.
Connect the ohm meter to points B and C. The ohm meter should read 3-4 ohm. Replace the handle loop that has a higher value.
C A1
Checking the heat loops in the rear handles
Checking the power switch
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.
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 highest, 0.1 ohm with the switch in position "1".
66 English
CENTRIFUGAL CLUTCH
Dismantling
Remove the bar and chain. See the operating instructions. On 268K and 272K, remove the cutting attachment. See the operating instructions. On 272S, remove the grinder attachment. See the operating instructions.
Remove the spark plug and insert the piston stop.
Use a spanner and remove the clutch. On saws 36 and 41 use the 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.
Remove the springs using a screwdriver. Then remove the clutch shoes.
Remove the spring by first lifting a shoe using a suitable spacer (A). Then remove the clutch shoes. A
Prise out the spring heels using a screwdriver. Remove the springs from the other side using circlip pliers. Then remove the clutch shoes.
Remove the clutch drum and needle bearing.
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67
CENTRIFUGAL CLUTCH
Clean all parts and inspect the following:
Clutch shoes without chamfers.
Clutch shoes with chamfers.
That measurement A is not below 1 mm. A
That measurement B is not under 1 mm.
Check that there is no play between the clutch shoe and clutch hub Check 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.
68 English
CENTRIFUGAL CLUTCH
Assembly
Grease the needle bearing (C) and fit onto the crankshaft. Then fit the clutch drum. NOTE! The bearing can also be greased later through the hole on the crankshaft.
To prevent imbalance all clutch shoes should be replaced at the same time.
Saws with three coil springs.
Saws with one long spring.
Saws with three C-springs.
NOTE! The clutch springs should not be opened out more than necessary. Risk of deformation.
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 suitable spacer (A) and fit the spring. A
Locate the clutch shoes on the hub and fit the springs with the help of circlip pliers.
Using a spanner secure the clutch centre. On saws 36 and 41 use service tool no. 530 03 11-12. Note! Left-hand thread.
Remove the piston stop and fit the spark plug.
Fit the chain and bar. See the operating instructions. On 268K and 272K, fit the cutting attachment. See the operating instructions.
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69
LUBRICATION SYSTEM
Dismantling
Dismantle the following parts: Starter. See the operating instructions Centrifugal clutch. See page 67.
Saws 36, 40, 41, 45, 51 and 55. See page 72
Saw 3120. See page 72
Other saws.
Remove the pump drive and washer.
Saws 61, 268, 272XP. See next page.
Saws 281XP and 288 XP. See next page.
Undo the three bolts (A) and remove the oil pump. Some pumps have to be removed by using extractor screws. M5 screws should be inserted into the 2 threaded holes in the pump body and tightened equally to lift the pump and thrust washer. Other pumps have a cut-out (C) for a screwdriver to prise off the pump. Both types are shown below.
Saw 394. See page 72.
Saws 42, 242XP, 246, 254XP, 262XP and 257. A B C
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 the seal (F). B A D E
70 English
LUBRICATION SYSTEM
Saws 61, 268, 272XP.
Dismantle the oil pump as follows: F 1. Remove the lock washer (A), washer, spring and adjuster screw (B). 2. Remove the locking lacquer and undo screw (C). 3. Knock the edge of the pump housing against a piece of wood so that 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). B G
A H
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 necessary, replace the seal (E). 5. If necessary, replace the O-ring (F). F A
D E
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71
LUBRICATION SYSTEM
Saw 394.
Dismantle the oil pump as follows: 1. Dismantle the screw (A) so that the spring and latch pin (B) can be removed. 2. Lever out the pump piston (C) with the plastic plug (D) using a screwdriver. 3. Remove the seal (E).
Saw 3120.
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.
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.
72 English
LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.
Dismantle the chain guide plates as shown in respective diagrams below.
36/41
40/45
51/55
Saws 36, 40, 41 and 45.
Saws 51 and 55.
Undo the two bolts and lift off the pump and the upper seal.
Lift off the pump and the upper seal.
Take the pump apart as shown in the exploded view on the next page.
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LUBRICATION SYSTEM
G B C
36/41
40/45
A. B. C. D. E. F. G.
Lower seal. Pump cylinder. Upper seal. Chain guide plate. Pump housing. Pump piston. Worm gear.
50/51
74 English
LUBRICATION SYSTEM
Dismantling the oil pump's 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.
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75
LUBRICATION SYSTEM
Clean all parts and check the following when appropriate to the saw in 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.
That the pump piston's pinion gear is undamaged.
That the worm gear on the oil pump drive is undamaged.
That all seals are undamaged.
The oil pipe is not blocked and the filter screen is clean.
76 English
LUBRICATION SYSTEM
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.
Assembling the oil pump

Saws 42, 242XP, 246, 254XP, 262XP and 257.
Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts. 2. Insert the pump piston (D) with washers and spring. 3. Press in the pump piston a little more and screw in the adjuster screw (C). 4. Insert the plastic plug (E). 5. Refit screw (A) and locking clip (B). 6. Fit the seal (F).
B A
Saws 61, 268, 272XP.
See continuation, page 80.
Fit the oil pump as follows: F 1. 2. 3. 4. 5. Apply SAE 30 oil to all moving parts. Fit the seal (G) if necessary. Press in pin (F). Locate the pinion (E) with washers and spring. Insert the pump piston (D) through the pinion, spring and washers in the pump housing. Fit screw (C). The screw should be locked using Loctite or locking lacquer. Fit the adjuster screw (I) with washers, spring and locking clip (A). Fit the O-ring (H). B G I
6. 7. 8.
A H
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77
LUBRICATION SYSTEM
Saws 281XP and 288 XP.
Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts 2. Fit the seal (E) if necessary. 3. Fit the plug (B) and spring with washers on the pump piston (C) and fit the unit in the 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). F A
D E
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). E
78 English
LUBRICATION SYSTEM
Saw 3120.
Fit the oil pump as follows: 1. Apply SAE 30 oil to all moving parts 2. Fit the seal (C). 3. Fit the pump piston (D) with spring. Press in the piston and hold it in position 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 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).
H G J
K B A
Fit the wire for manual oil supply.
See continuation on next page.
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LUBRICATION SYSTEM
Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and 3120.
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.
1. Lubricate the pinion gear with grease. 2. Fit the oil pump on the saw 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.
80 English
LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.
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 crankcase. A. B. C. D. E. F. G. Lower seal. Pump cylinder. Upper seal. Chain guide plate. Pump housing. Pump piston. Worm gear
G B C
36/41
40/45
50/51
Saws 36, 40, 41 and 45, see continuation on the next page.
Saws 51 and 55, see continuation on the next page.
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LUBRICATION SYSTEM
Saws 36, 40, 41 and 45. Saws 51 and 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.
Fit the chain guide plates according to respective diagrams below.
36/41
40/45
51/55
Fit the bar and chain.
82 English
CARBURETTOR
Description
The diagrams in this description do not correspond with the carburettor fitted on the chain saws. They serve only to show the principles of design and operation.
Design The carburettor consists of three sub-systems: Metering unit, A. Mixing venturi, B. Pump unit, C.
The metering unit (A) contains the jets and fuel control functions. It is here the correct amount of fuel for the given engine speed and power is metered.
A The mixing venturi (B) houses 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.
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 crankcase. The other side of the diaphragm pumps the fuel.
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83
CARBURETTOR
Operation The carburettor operates differently in the following modes: Cold start Idling Part throttle Full throttle
In the cold start mode the choke valve (D) is fully closed. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets (E, F and G). The throttle valve (H) is partly open.
In the idling mode (H) the throttle valve is closed. Air is sucked in through an aperture in the throttle valve and a small amount of 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).
H In the full throttle mode both valves are open and fuel is supplied through all three diffuser jets (E, F and G).
84 English
CARBURETTOR
Dismantling
Dismantle all parts necessary and remove the carburettor from the saw. On some models the cylinder needs to be loosened and lifted to be able to remove the carburettor.
See the carburettor in question on the next four pages and the instructions below.
Semi fixed jet/fixed jet
Plugs When cleaning the carburettor the plugs must be removed. Remove as follows: 1. Drill a hole in the plug. 2. Insert a screwdriver or punch in the hole and prise up the plug.
Some carburettors have an extra jet (semi fixed jet). The jet is of brass and is located in the metering unit and is used to give a fuel supplement. On average 10% of 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.
English
85
CARBURETTOR
Tillotson HS 228 B
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 the fuel screen (D). 5. Unscrew the high and low speed jet screws. 6. Remove the plugs (J). See page 85. 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. B A J C H E F G D
Tillotson HS 255 B
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 the fuel screen (D). 5. Unscrew the high and low speed jet screws. 6. Remove the plugs (J). See page 85. 7. If necessary remove the throttle and choke 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. B A J H C H K D E F G I
86 English
CARBURETTOR
Tillotson HS 260 A
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). J 4. Using a needle or the like carefully remove the fuel screen (D). C 5. Unscrew the high and low speed jet screws. 6. Remove the plugs (J). See page 85. 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. 8. Remove the semi fixed jet (K). See page 85. B A H K H E F G D
Walbro HDA and HD

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 the fuel screen (D). D 5. Unscrew the high and low speed jet screws. G 6. Remove the plug (J). See page 85. F 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. E
A B
H C
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87
CARBURETTOR
Walbro WJ
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 the fuel screen (D). 5. Unscrew the high and low speed jet screws. 6. Remove the plug (J). See page 85. 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. 8. Remove the semi fixed jet (K). See page 85. B A D E F G
K H
Walbro WG
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 the fuel screen (D). 5. Unscrew the low speed jet screws. 6. Remove the plugs (J). See page 85. D 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. 8. Remove the semi fixed jet (K). See page 85. E G F
A B
H C K J
88 English
CARBURETTOR
Walbro WT
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 the fuel screen (D). 5. Unscrew the high and low speed jet screws. 6. Remove the plug (J). See page 85. 7. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. 8. Remove the semi fixed jet with diffuser jet (K). See page 85. B A H K C J D E
F G
ZAMA C1Q-EL1
A 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 the fuel screen (D). 5. Unscrew the high and low speed jet screws. 6. If necessary remove the throttle and choke valves as well as the shafts, lever arms and springs. C K D G F E B
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CARBURETTOR
Clean all components in petrol. Wear gloves or skin protection cream.
!
Use compressed air to dry the petrol on the components. Direct the air through all channels in the carburettor housing and ensure that they are not blocked.
WARNING! Never direct the compressed air jet towards the body. Air can be forced into the blood stream and can cause fatality.
Refer to the carburettor diagram in question on the previous pages and check the following: 1. That the gasket and pump and control diaphragms are undamaged. 2. That there is no play on the throttle and choke valve 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.
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CARBURETTOR
Assembly
Refer to the carburettor in question on the next eight pages. A pressure test, see page 100, should be carried out after assembling and before the carburettor is refitted to the saw.
WARNING! The fuel used in the chain saw poses the following hazards: 1. The fluid and its vapours are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable.
Plugs When cleaning the carburettor the plugs must be removed. Reassemble as follows: 1. Place the plug in the hole with the convex side facing upwards. 2. Expand the plug by using a punch on the top side.
Semi fixed jet/fixed jet Some carburettors have an extra jet (semi fixed jet). The jet is of brass and is located in the metering unit and is used to give a fuel supplement. On average 10% of the fuel passes through the 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.
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91
CARBURETTOR
Tillotson HS 228 B
E F G D
Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips. 4. Fit the fuel screen (D) by using the handle of a small screwdriver. 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 metering unit. 9. Carry out a pressure test. See page 100. J C H B A
92 English
CARBURETTOR
Tillotson HS 255 B
D E F G I
Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the semi fixed jet (K). See page 91. 4. Fit the high and low jet 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 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 and 272S). 10. Fit the control diaphragm (B) with gasket and cover (A) on the metering unit. 11. Carry out a pressure test. See page 100.
J H C H B A K
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93
CARBURETTOR
Tillotson HS 260 A
E F G D
Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the semi fixed jet (K). See page 91. 4. Fit the high and low jet 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 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) on the metering unit. 10. Carry out a pressure test. See page 100. C H B A
J H
94 English
CARBURETTOR
Walbro HDA och HD
Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips. 4. Fit the fuel screen (D) by using the handle of a small screwdriver. 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 metering unit. 9. Carry out a pressure test. See page 100. H C A B
G F E
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95
CARBURETTOR
Walbro WJ
E F Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the semi fixed jet (K). See page 91. 4. Fit the high and low jet 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 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) on the metering unit. 10. Carry out a pressure test. See page 100. C K H B A G D
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CARBURETTOR
Walbro WG
A Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the plugs (J). See page 91. 3. Fit the fixed jet (K). See page 91. 4. Fit the high and low jet 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 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) on the metering unit. 10. Carry out a pressure test. See page 100. B
H C K J
D G F E
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97
CARBURETTOR
Walbro WT
E Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. C 2. Fit the plugs (J). See page 91. J 3. Fit the semi fixed jet (K). See page 91. 4. Fit the high and low jet 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 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) on the metering unit. 10. Carry out a pressure test. See page 100.
F G
B A
98 English
CARBURETTOR
ZAMA C1Q-EL1
Maintain a high level of cleanliness when reassembling the carburettor. Even small particles of dirt can cause operating problems. 1. If the throttle and choke valves, shafts, lever arms and springs have been dismantled these must be reassembled. Lubricate the shaft bearings using a light oil. 2. Fit the high and low jet screws and springs. NOTE! Do not tighten the screws against the seats. This can damage the seats and needle tips. 3. Fit the fuel screen (D) by using the handle of a small screwdriver. 4. Fit the 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. 8. Carry out a pressure test. See page 100.
A B
C K D G F E
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99
CARBURETTOR
Pressure testing
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.
Make the test as follows: 1. Set the high and low speed jet screws one turn open from the bottom. 2. Connect pressure tester 502 50 38-01 to the carburettors fuel intake. 3. Lower the carburettor into a beaker of water. 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.
Leakage on Diffuser jets Leakage on the pulse tube Ventilation hole above the metering unit
Fault with Needle valve Pump diaphragm
Control diaphragm
Refitting onto chain saw

Fit the carburettor to the chain saw and refit any other parts removed. For tightening torques, see the Service data for the saw in question.
Carburettor adjustment. See the operating instructions for the saw in question.
100 English
AIR FILTER
Replace the chain saws air filter at the intervals stated in respective operating instructions. It is extremely important that the air filter units on power cutters 268K, 272K and stump grinder 272S are maintained correctly. The air filter units on these models have therefore been included in this workshop manual.
268K, 272K and 272S

The air filter system consists of: 1. Prefilter. 2. Main filter.
Prefilter The prefilter is an oiled foam 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 regularly 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! Compressed air at a high pressure can damage the foam.
Oiling Oil the filter carefully. It is extremely important that the entire filter is saturated with oil. Use HUSQVARNA oil no. 503 4773-01. The bottle holds 0.1l, which is sufficient for three applications.
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101
AIR FILTER
Main filter
The main filter is a paper filter and is accessible under the cover (B). This filter should be replaced/cleaned when the saws power decreases 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
102 English
TANK UNIT
Dismantling
Empty the tank and dismantle the cylinder cover as well as the bar and chain.
Loosen the fuel pipe and disconnect the throttle cable if fitted.
The figures on the next page illustrate all types of mountings between the tank unit and the engine sub-assembly marked by letters.
The mountings applying to the chain saw in question is evident from the table on the next page.
If heated handles are fitted remove the connections. The cable to the switch cannot be removed before the tank unit and the engine subassembly are separated.
NOTE! Take care that the fuel pipe and throttle cable are not damaged.
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.

Clean all parts and check the following: That the fuel pipe is undamaged. That the tank unit is not cracked. That the throttle cable runs freely. That the AV-system is undamaged For AVsystem see page 107. That the tank breather is not blocked or leaks. That the fuel cap does not leak. That the fuel pipe bushing seals That the fuel filter is not blocked.
If the fuel pipe needs to be replaced, measure its length outside of the tank unit and make a note of the length. This information is needed when fitting a new pipe.
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103
TANK UNIT
A B C D E
L K J I F G H
Saw
36 40 41 42 45 51 55 61 242XP 246 254XP
Bolts placed at
A, D, F, 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
Saw
257 262XP 268 268K 272XP 272K 272S 281XP 288XP
Bolts placed at
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
394XP B, E, G, I, H 3120XP C, D, F, I, J
104 English
TANK UNIT
Assembly
If a new fuel pipe is to be fitted proceed as follows: 1. Measure the length of the old hose outside of the tank unit, note the length. 2. Oil half of the hose lightly and thread the oiled part into the fuel tank from the outside. 3. Twist the hose so that it takes on the same angle to the carburettor and let the hose protrude as much as the old hose did. 4. Pull the hose through the filler hole using tool 502 50 83-01, cut off the bevelled end and fit the fuel filter.
Fit the throttle and lock.
NOTE! Ensure that the fuel pipe and throttle cable are not damaged.
Fit the engine sub-assembly 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.
The figures on the previous page illustrate all types of mountings between the tank unit and the engine sub-assembly marked by letters. The mountings applying to the chain saw in question is evident from the table on the next page.
Make the handle heater connections if necessary.
Fit the bolts as set out in the table on the previous page. Tightening torques, see the service data for the saw in question.
Connect the fuel pipe and the throttle cable to the carburettor.
Fit the cylinder cover and the chain and bar.
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105
ANTI-VIBRATION SYSTEM
Description
The anti-vibration system reduces the vibrations which pass from the engine and cutting equipment to the handles. The anti-vibration system consists either of rubber elements or coil springs. The systems movement limitation consists of side absorbers and/or stop screws.
Dismantling
The tank unit must be removed from the engine sub-assembly to access the anti-vibration system. See the previous pages.
Saw 394
Saws 40, 45 and 3120
Other saws
Release the catch on the plastic key.
Remove the rubber element using respective tools as shown in the figure below.
Slide off the spring and its holder.
Remove the spring element using an allen key as shown below.
106 English
ANTI-VIBRATION SYSTEM
Assembly
Fit the rubber stop with the help of a wire or the like. Fitting the anti-vibration systems side absorber.
Fitting the anti-vibration systems damper element. Tightening torques, see the Service data for respective saws.
Saw 394
Saws 40, 45 and 3120
Other saws
Slide in the spring and its holder.
Fit the rubber element using the tools shown in the figure below.
Fit the spring element using an allen key as shown in the figure below.
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107
PISTON AND CYLINDER

Dismantling
Dismantle the following parts: Cylinder cover. See operating instructions. Spark plug. See operating instructions. Carburettor. Muffler.
Saws 36, 40, 41 and 45.
Other saws
Dismantle the insulation plate between the cylinder and the carburettor and the intake manifold.
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). B A
Remove the cables to the ignition coil. Remove the ignition coil. NOTE! Ensure that no dirt or other foreign particles fall into the crankcase. Saws 36 and 41. Saws 40 and 45.
Dismantle the tank unit. See page 102.
Undo the four bolts under the crankcase.
Carefully lift up the cylinder.
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 remove the piston.
Remove the needle bearing from the little end of the connecting rod. Remove the decompression valve if fitted.
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PISTON AND CYLINDER

Clean all parts, scrape off any gasket residue remove carbon deposits from the following areas: 1. The piston crown. 2. The top of the cylinder bore. 3. The cylinder exhaust port. 4. The decompression valve channel.
Check the following: 1. That the cylinders surface coating is not worn, especially the upper part of the cylinder. 2. That the cylinder is free of score marks. 3. That 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. Max 1 mm
Pressure test the decompression valve as follows: 1. Connect the tool 502 50 38-01 to the decompression valve 2. Pump up the pressure to 80 kPa (0.8 bar). 3. Wait 30 seconds. 4. The pressure should not drop below 60 kPa (0.6 bar).
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109
PISTON AND CYLINDER

On saws 40 and 45, check the rubber sealing on the shaft seat. Change the shaft seat, if necessary.
Faults and causes

Score marks on the piston. 1. Incorrect carburettor setting max. speed too high 2. Too low octane fuel. 3. Too little or incorrect oil in the fuel.
Carbon build-up 1. Incorrect carburettor setting max. speed too low. 2. Too much or incorrect oil in the fuel.
Piston ring breakage 1. Excessive engine speed 2. Piston ring worn out. 3. Oversized piston ring groove.
110 English
PISTON AND CYLINDER

Assembly
NOTE! Ensure that no dirt or other foreign particles fall into the crankcase.
Oil the needle bearing and fit it into the connecting rod little end. Refit the piston with the arrow facing the exhaust port. Slide in the gudgeon pin and fit the circlip.
Other saws Saws 36, 40, 41 and 45
Fit a new cylinder gasket
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.
Saws 36 and 41
Apply silicone rubber 504 98 26-01 to the lower crankcase halfs contact surfaces. Check that the seals fit in their grooves correctly. Tighten the crankcase halves. Tightening torque refer to Service data.
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111
PISTON AND CYLINDER

Saws 36, 40, 41 and 45. Other saws
Fit the four bolts under the crankcase. Tightening torque, see Service data.
Saws 36 and 41.
Saws 40 and 45. Fit the four cylinder bolts (B). On saw 394, connect the anti-vibration spring (A) to the cylinder. The bolts are tightened using a 4 mm allen key (smaller saws) or 3/16 allen key (larger saws). B A
Fit the tank unit.
Fit the ignition coil and its cables.
Fit the intake manifold and the insulation wall between the cylinder and carburettor.
Fit the decompression valve.
Carry out a pressure test as set out on the next page.
Fit the following parts: Cylinder cover. See operating instructions. Spark plug. See operating instructions.
Carburettor. Muffler.
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 question.
112 English
PISTON AND CYLINDER

Pressure testing
Decompression valve Test the decompression valve as follows. 1. Connect the tool 502 50 38-01 to the decompression valve 2. Pump up the pressure to 80 kPa (0.8 bar). 3. Wait 30 seconds. 4. The pressure should not drop below 60 kPa (0.6 bar).
Crankcase and cylinder The following parts must be removed to pressure test the crankcase and cylinder: Carburettor. Muffler.
Carry out the test as follows: 1. Fit the cover plates (service tool) on the intake manifold and exhaust port. 2. Connect tool 502 50 38-01 to the cover plate on the intake manifold. The decompression 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:
Carburettor. Muffler
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113
CRANKCASE AND CRANKSHAFT

This section deals with the following: Crankcase and crankshaft (describes how the whole assembly is dismantled and assembled). Bar bolts (only describes replacing the bar bolts). See page 121. Seals. Describes changing the seals without splitting the crankcase. See page 122.
Dismantling
Before the crankcase can be split the following must be removed: A. Chain and bar. See operating instructions. B. Starter. See page 57. C. Electrical system. See page 61. D. E. F. G. H. I. Centrifugal clutch. See page 67. Oil pump. See page 70. Carburettor. Muffler. See page 49. Piston and cylinder. See page 108. Tank unit. See page 103.
Saws 36, 40, 41 and 45. See next page.
Other saws
Saw 394.
NOTE! Ensure that no dirt or foreign particles enter the bearings.
On saw 394, remove the carburettor chamber floor (A) and air jet (B). Other saws. A B Undo the bolts holding the crankcase together. The bolts are on the clutch side. Note the location of the bolts that are of a different length.
Split the crankcase using tool 502 51 61-01.
114 English

Press out the crankshaft by using tool 502 51 61-01. If necessary remove the crankshaft bearing from the crankcase. Proceed as follows:
!
Saws 36 and 41. Saws 40 and 45.
WARNING! The crankcase halves can be hot. Risk of burns. Wear protective gloves.
Remove all rubber and plastic components from the crankcase halves. Heat the crankcase half in question to 200C. Wear protective gloves and knock the crankcase half gently, inside face down, on a wooden bench or the like, and the bearing will drop out. Fit the new bearing into the crankcase half while it is still hot.
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.
Remove the bearing from the crankshaft using puller 502 90 90-01.
If necessary remove the following parts: A. Chain tension screw B. Bar bolts C. Spike
English
115

NOTE! Ensure no dirt or foreign particles enter the bearings, if fitted in the crankcase halves.
Clean all parts and scrape of any gasket residue from the mating surfaces of the crankcase halves.
Check the following: That the big end bearing 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 not hardened. That the crankcase is not cracked.
116 English

Assembly
Saws 36 and 41. Saws 40 and 45. Other saws
See page 120.
Fit the bearing and seals on the crankshaft. Grease the seals. Continue assembly as described on page 111.
WARNING! The crankcase halves can be hot. Risk of burns. Wear protective gloves.
If the bearing needs to be fitted proceed as follows: A. Heat the crankcase half in question to 200C. B. Wear protective gloves, take out the crankcase half and press in the bearing. NOTE! Ensure that dirt and foreign particles do not enter the bearing. C. Let the crankcase half cool before continuing work.
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 seals can also be fitted when the crankcase is in position. Assembly position. See pages 123 and 124.
English
117

Saw 40 and 45. Other saws.
See page 120.
NOTE! Ensure that the connecting rod does not jam against the crankcase when the crankcase and crankshaft are assembled.
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 assemble the crankshaft in the clutch sides crankcase half. Some saws have a sharp edge on the crankshaft which can damage the seal. The assembly sleeve should be used when working on these saws. See Tools. NOTE! Place the oil tanks vent hose in the pocket above the tank cap in the equivalent crankcase half.
NOTE! Continuing to pull with the assembly tool after the gasket is clamped will damage the crankshaft.
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.
118 English

Saw 40 and 45. Other saws.
See next page.
Fit the crankcase bolts. Tighten crosswise with the torque set out in the Service data. Tighten the bolts closest to the crankshaft first.
NOTE! Ensure excess gasket material does not fall into the crankcase.
Cut off excess gasket at the level of the cylinder seating plane. On saw 394, fit the floor of the carburettor chamber using the four bolts. A B
Fit the following parts A. B. C. Chain and bar. See operating instructions. Starter. See page 59. Electrical system. See page 63.
D. E. F. G. H. I.
Centrifugal clutch. See page 69. Oil pump. See page 77. Carburettor. Muffler. See page 49. Piston and cylinder. See page 111. Tank unit. See page 105.
If a crankshaft 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.
English
119

Saws 40 and 45.
NOTE! Ensure that dirt and foreign particles do not enter the bearing.
Fit the bearing on the crankshaft by using the assembly tool. See Tools.
Check the shaft seats sealing (A). Fit the shaft seat over the bearing and join the shaft seat at (B).
Continue assembly as described on page 111.
120 English

Bar bolts
When changing the bar bolts on all saws except 40 and 45 proceed as follows:
1. Drain the chain oil. 2. Knock through the old bar bolt so that it falls in the oil tank. 3. Remove the bolt from 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 bolts 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 crankcase. 8. Refill with chain oil.
English
121

Changing the seals
This section describes how to change the seals without splitting the crankcase.
Dismantling
Before dismantling the seals remove the following parts: On the starter side: Starter Flywheel Generator (if fitted) On the clutch side: 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 seals 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.
122 English

Assembly Seal assembly in the oil pump 1. Place the oil pump on a sleeve (A) with an inner diameter greater than the seals outer diameter. 2. Fit the seal (B) using the assembly punch so that the surfaces (C), are level. B C
Seal assembly in the plastic flange 1. Place the plastic flange on a flat and firm surface. 2. Fit the seal using the assembly punch until it bottoms on the flange shoulder.
Seal assembly in the crankcase Some saws have a sharp edge on the crankshaft which can damage the seal. The assembly sleeve should be used when working 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.
After fitting the seal assemble: On the starter side: Starter Flywheel Generator (if fitted) On the clutch side: Chain and bar Oil pump
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123

Assembly positions starter side Measurement A should be as in the table below for resp. saws (Under the crankcase plane). 61, 268 272 281, 288 4-4.5 mm 2 mm 3.5 mm
Measurement B should be as in the table below for resp. saws (Under the crankcase plane). 42, 242, 246 394 3120 1 mm 5 mm 0-0.5 mm
51, 55
1 mm above the crankcase plane
1 mm
Assembly position on the clutch side
Measurement C should be as in the table below for resp. saws (Under the crankcase plane). 51, 55 394 1 mm 0.5 mm
254, 257, 262 1.5 mm above the crankcase plane.
1.5 mm
124 English

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Husqvarna Chain Saws

36 40 41 42 45 51 55 61 242XP 246 254XP

Bore mm 38.0 40.0 40.0 42.0 42.0 45.0

Stroke mm 32.0 32.0 32.0 30.0 32.0 32.0

Max. power at r/min 9000 9000 9000 9300 9000 9000

Ignition system PHELON PHELON PHELON SEM AM 7 PHELON ELECTROLUX ET

Bar length cm/inches 36 40 41 42 45 51 33-46/13-18 33-46/13-18 33-46/13-18 28-46/11-18 33-46/13-18 33-51/13-20

Chain pitch inches .325-3/8 .325 .325-3/8 .325 .325 .325-3/8

Idling speed r/min 36 40 41 42 45 51 3000 2500 3000 2700 2500 2500

Engagement speed r/min 4500 3600 4500 3800 3600 3700

Max. speed r/min 13000 12500 13000 14500 12500 12500

Spark plug Champion RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y

Oil pump capacity cm /min at 8.500 rpm

Automatic oil pump

Yes Yes Yes Yes Yes Yes

Handle heater Watt/ r/min No No No No No No

Displacement cm3 55 61 242XP 246 254XP 257 53 62 42 46 54 57

Bore mm 46.0 48.0 42.0 44.0 45.0 46.0

Stroke mm 32.0 34.0 30.0 30.0 34.0 34.0

Max. power at r/min 9000 8300 9900 9000 9300 9000

Ignition system ELECTROLUX ET ELECTROLUX ET SEM AM 7 SEM AM 7 ELECTROLUX ET ELECTROLUX ET

Chain pitch inches .325-3/8 3/8 .325 .325 .325-3/8 .325-3/8

Engagement speed r/min 3700 3700 3900 3900 3700 3700

Max. speed r/min 12500 12000 15500 15000 13800 13500

Spark plug Champion RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y

Automatic oil pump

Yes Yes Yes Yes Yes Yes

Handle heater Watt/ r/min No No 65/10.000 No 65/10000 65/10000

Displacemennt cm3 262XP 268 272XP 268K 272K 272S 62 67 72 67 72 72

Bore mm 48.0 50.0 52.0 50.0 52.0 52.0

Stroke mm 34.0 34.0 34.0 34.0 34.0 34.0

Max. power at r/min 9600 9000 9300 9000 9300 9300

Ignition system ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET ELECTROLUX ET

Chain speed m/s 18.5/9600 rpm 18.4/9000 rpm 20.0/9300 rpm -

Chain pitch inches .325-3/8 3/8 3/8 -

Engagement speed r/min 3400 3500 3500 3500 3500 3500

Max. speed r/min 13500 12500 13500 10000 10000 10000

Spark plug Champion RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y RCJ 7 Y

Oil pump capacity cm3/min at 8.500 rpm 6.5-13.5 4/9/13/17 5/9/14/19 -

Oil tank volume Litres 0.3 0.45 0.45 -

Automatic oil pump

Yes Yes Yes -

Handle heater Watt/ r/min 65/10000 65/10000 65/10000 -

9.5 9.6 21.0 (including carriage)

Displacement cm3 281XP 288XP 394XP 3120XP 81 87 94 119

Bore mm 52.0 54.0 56.0 60.0

Stroke mm 38.0 38.0 38.0 42.0

Max. power at r/min 9000 9300 8800 9000

Ignition system SEM AM 7 SEM AM 7 SEM AM 44 SEM AM 37

Carburettor TILLOTSON HS 228 TILLOTSON HS 228 WALBRO WJ 39 WALBRO WG 6

Chain pitch inches 3/8 3/8 3/8-.404 .404

Engagement speed r/min 3200 3200 3400 3300

Max. speed r/min 12500 12500 12500 11500-12500

Spark plug Champion RCJ 6 Y RCJ 6 Y RCJ 6 Y RCJ 7 Y

Oil tank volume Litres 0.5 0.5 0.5 0.7

Automatic oil pump

Yes Yes Yes Yes

Handle heater Watt/ r/min 56/7200 56/7200 65/10000 No

502 50 22-01 8 mm 502 50 23-01 10 mm

compl 502 51 49-02 502 51 49-01 *502 51 54-01

502 50 33-01 compl 502 51 49-02 compl 502 51 49-02