Husqvarna - Drujbe PDF

Husqvarna Chain Saws
Workshop Manual
101 88 55-26
Eng, front
96-09-13, 10.38
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
Eng, p 2-39
96-09-13, 09.05
INTRODUCTION
General
Updates
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.
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.
This workshop manual applies to the engine

assembly in the following chain saws:
257
262XP
268
36
40
41
42
272XP
268K
272K
272S
45
51
55
61
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:
281XP
288XP
242XP
246
254XP
Spare parts
Service tools
Accessories
394XP
3120XP
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
Eng, p 2-39
96-09-13, 09.05
INTRODUCTION
Use
Dismantling and reassembly of the entire
This workshop manual can be used in two different

ways:
Repair of a specific sub-assembly

Dismantling and reassembly of the entire chain
saw
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.
2.
Work forwards through the manual and

carry out Dismantling instructions in the
order that the sections occur.
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.
3.
2.
Carry out the steps: Dismantling

Cleaning and inspection
Reassembly
Return to the Starter on page 58 and

follow the instructions under Cleaning
and Inspection.
4.
Work forward through the manual and

carry out Cleaning and Inspection in the
order that the sections occur.
5.
Order or collect all the required spare

parts from the spare parts stores.
6.
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.
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
Eng, p 2-39
96-09-13, 09.05
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.
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.
After testing, do not touch the

silencer until it has cooled. Risk
of burns. This especially applies if
the saw is fitted with a catalytic converter.
The coating on and in the catalytic element
is hazardous to touch. Use protective gloves
when working on the catalytic converter.
Inadequate chain lubrication can result in

the chain breaking, which can cause
serious or fatal injury.
Make sure that the 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
Eng, p 2-39
96-09-13, 09.05
TECHNICAL DATA
Displacement
cm3
Bore
mm
Stroke
mm
Max. power at
r/min
36
40
41
36
40
40
38.0
40.0
40.0
32.0
32.0
32.0
9000
9000
9000
42
45
51
42
44
51
42.0
42.0
45.0
30.0
32.0
32.0
9300
9000
9000
Spark plug gap
Ignition system
mm/inches
Air gap
Carburettor
mm/inches
36
40
41
0.5/ .02
0.5/ .02
0.5/ .02
PHELON
PHELON
PHELON
0.3/ .012
0.3/ .012
0.3/ .012
WALBRO WT 239
ZAMA C1Q-EL1
WALBRO WT 239
42
45
51
0.5/ .02
0.5/ .02
0.5/ .02
SEM AM 7
PHELON
ELECTROLUX ET
0.3/ .012
0.3/ .012
0.3/ .012
WALBRO HDA 98
ZAMA C1Q-EL1
WALBRO WT 170
Bar length
cm/inches
Chain speed
m/s
Chain pitch
inches
Drive link gauge

mm/inches
36
40
41
33-46/13-18
33-46/13-18
33-46/13-18
17.3/9000 rpm
17.4/8500 rpm
17.3/9000 rpm
.325-3/8
.325
.325-3/8
1.3/ .050
1.3/ .050
1.3/ .050
42
45
51
28-46/11-18
33-46/13-18
33-51/13-20
17.9/9300 rpm
17.4/8500 rpm
17.4/9000 rpm
.325
.325
.325-3/8
1.5/ .058 / 1.3/ .0501)

1.3/ .050
1.5/ .058 / 1.3/ .0501)
1)
6 English
Eng, p 2-39
96-09-13, 09.05
From May 1996
TECHNICAL DATA
Idling speed
r/min
Engagement speed
r/min
Max. speed
r/min
Spark plug
Champion
36
40
41
3000
2500
3000
4500
3600
4500
13000
12500
13000
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
42
45
51
2700
2500
2500
3800
3600
3700
14500
12500
12500
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
Fuel tank volume

Litres
Oil pump capacity

cm /min at 8.500 rpm
3
Oil tank volume

Litres
Automatic oil pump
36
40
41
0.4
0.5
0.4
7
8
7
0.2
0.25
0.2
Yes
Yes
Yes
42
45
51
0.5
0.5
0.6
3-7
8
10
0.27
0.25
0.3
Yes
Yes
Yes
Weight without bar and chain

kg
Weight with bar and chain
Handle heater
kg/lbs
Watt/ r/min
36
40
41
4.6
4.7
4.6
5.3 (13")
5.4 (13")
5.3 (13")
No
No
No
42
45
51
4.7
4.7
5.2
5.5 (13")
5.4 (13")
6.2 (15")
No
No
No
English
Eng, p 2-39
96-09-13, 09.05
TECHNICAL DATA
Displacement
cm3
Bore
mm
Stroke
mm
Max. power at
r/min
55
61
242XP
53
62
42
46.0
48.0
42.0
32.0
34.0
30.0
9000
8300
9900
246
254XP
257
46
54
57
44.0
45.0
46.0
30.0
34.0
34.0
9000
9300
9000
Spark plug gap
Ignition system
mm/inches
Air gap
Carburettor
mm/inches
55
61
242XP
0.5/ .02
0.5/ .02
0.5/ .02
ELECTROLUX ET
ELECTROLUX ET
SEM AM 7
0.3/ .012
0.3/ .012
0.3/ .012
WALBRO WT 170
TILLOTSON HS 254
WALBRO HDA 98
246
254XP
257
0.5/ .02
0.5/ .02
0.5/ .02
SEM AM 7
ELECTROLUX ET
ELECTROLUX ET
0.3/ .012
0.3/ .012
0.3/ .012
WALBRO HDA 98
WALBRO HDA 35B
WALBRO HDA 120
Bar length
cm/inches
Chain speed
m/s
Chain pitch
inches
Drive link gauge

mm/inches
55
61
242XP
38-51/15-20
38-51/15-20
28-46/11-18
17.4/9000 rpm
18.4/8300 rpm
19.1/9900 rpm
.325-3/8
3/8
.325
1.5/ .058 / 1.3/ .050 1)

1.5/ .058
1.5/ .058 / 1.3/ .050 1)
246
254XP
257
28-46/11-18
33-51/13-20
33-51/13-20
17.3/9000 rpm
17.3/9300 rpm
17.3/9000 rpm
.325
.325-3/8
.325-3/8
1.5/ .058 / 1.3/ .050 1)

1.5/ .058
1.5/ .058
1)
8 English
Eng, p 2-39
96-09-13, 09.05
From May 1996
TECHNICAL DATA
Idling speed
r/min
Engagement speed
r/min
Max. speed
r/min
Spark plug
Champion
55
61
242XP
2500
2500
2700
3700
3700
3900
12500
12000
15500
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
246
254XP
257
2700
2700
2700
3900
3700
3700
15000
13800
13500
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
Fuel tank volume

Litres
Oil pump capacity

cm3/min at 8.500 rpm
Oil tank volume

Litres
Automatic oil pump
55
61
242XP
0.6
0.75
0.5
10
4/8/12/17
3-7
0.3
0.45
0.27
Yes
Yes
Yes
246
254XP
257
0.5
0.6
0.6
3-7
3-10
3-10
0.27
0.3
0.3
Yes
Yes
Yes

kg
Weight with bar and chain

kg/lbs
Handle heater
Watt/ r/min
55
61
242XP
5.2
6.1
4.7
6.2 (15")
7.1 (15")
5.5 (13")
No
No
65/10.000
246
254XP
257
4.7
5.4
5.6
5.5 (13")
6.3 (13")
6.6 (13")
No
65/10000
65/10000
English
Eng, p 2-39
96-09-13, 09.05
TECHNICAL DATA
Displacemennt
cm3
Bore
mm
Stroke
mm
262XP
268
272XP
62
67
72
48.0
50.0
52.0
34.0
34.0
34.0
9600
9000
9300
268K
272K
272S
67
72
72
50.0
52.0
52.0
34.0
34.0
34.0
9000
9300
9300
Spark plug gap
Ignition system
mm/inches
Air gap
Carburettor
mm/inches
262XP
268
272XP
0.5/ .02
0.5/ .02
0.5/ .02
ELECTROLUX ET
ELECTROLUX ET
ELECTROLUX ET
0.3/ .012
0.3/ .012
0.3/ .012
WALBRO HDA 120

TILLOTSON HS 260
TILLOTSON HS 260
268K
272K
272S
0.5/ .02
0.5/ .02
0.5/ .02
ELECTROLUX ET
ELECTROLUX ET
ELECTROLUX ET
0.3/ .012
0.3/ .012
0.3/ .012
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
-
10 English
Eng, p 2-39
Max. power at
r/min
10
96-09-13, 09.05
Drive link gauge

mm/inches
1.5/ .058
1.5/ .058
1.5/ .058
-
TECHNICAL DATA
Idling speed
r/min
Engagement speed
r/min
Max. speed
r/min
Spark plug
Champion
262XP
268
272XP
2700
2500
2500
3400
3500
3500
13500
12500
13500
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
268K
272K
272S
2500
2500
2500
3500
3500
3500
10000
10000
10000
RCJ 7 Y
RCJ 7 Y
RCJ 7 Y
Fuel tank volume

Litres
Oil pump capacity

262XP
268
272XP
0.6
0.75
0.75
6.5-13.5
4/9/13/17
5/9/14/19
268K
272K
272S
0.75
0.75
0.75
Weight without chain and bar

kg
Oil tank volume

Litres
0.3
0.45
0.45
5.8
6.2
6.3
268K
272K
272S
9.5
9.6
21.0 (including carriage)
Yes
Yes
Yes
Weight with chain and bar

kg/lbs
262XP
268
272XP
Automatic oil pump
Handle heater
Watt/ r/min
6.8 (13")
7.2 (15")
7.3 (15")
65/10000
65/10000
65/10000
English
Eng, p 2-39
11
96-09-13, 09.43
11
TECHNICAL DATA
Displacement
cm3
Bore
mm
Stroke
mm
Max. power at
r/min
281XP
288XP
81
87
52.0
54.0
38.0
38.0
9000
9300
394XP
3120XP
94
119
56.0
60.0
38.0
42.0
8800
9000
Spark plug gap
Ignition system
mm/inches
Air gap
mm/inches
281XP
288XP
0.5/ .02
0.5/ .02
SEM AM 7
SEM AM 7
0.3/ .012
0.3/ .012
TILLOTSON HS 228
TILLOTSON HS 228
394XP
3120XP
0.5/ .02
0.5/ .02
SEM AM 44
SEM AM 37
0.3/ .012
0.3/ .012
WALBRO WJ 39
WALBRO WG 6
Bar length
cm/inches
Chain speed
m/s
Chain pitch
inches
281XP
288XP
38-71/15-28
38-71/15-28
20.0/9000 rpm
20.7/9300 rpm
3/8
3/8
394XP
3120XP
46-91/18-36
60-107/24-42
19.6/8800 rpm
20.1/9000 rpm
3/8-.404
.404
12 English
Eng, p 2-39
Carburettor
12
96-09-13, 09.43
Drive link gauge

mm/inches
1.5/ .058
1.5/ .058
1.5/ .058 - 1.6/.063
1.6/ .063
TECHNICAL DATA
Idling speed
r/min
Engagement speed
r/min
Max. speed
r/min
Spark plug
Champion
281XP
288XP
2500
2500
3200
3200
12500
12500
RCJ 6 Y
RCJ 6 Y
394XP
3120XP
2500
2500
3400
3300
12500
11500-12500
RCJ 6 Y
RCJ 7 Y
Oil pump capacity

Oil tank volume

Litres
Automatic oil pump
9/12/15/18
9/12/15/18
0.5
0.5
Yes
Yes
0.5
0.7
Yes
Yes
Fuel tank volume

Litres
281XP
288XP
0.9
0.9
394XP
3120XP
0.9
1.25

kg
14-21
8-51
Weight with bar chain

kg/lbs
Handle heater
Watt/ r/min
281XP
288XP
7.5
7.5
8.7 (18")
8.7 (18")
56/7200
56/7200
394XP
3120XP
7.9
10.4
9.2 (18")
12.3 (28")
65/10000
No
English
Eng, p 2-39
13
96-09-13, 09.43
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
Eng, p 2-39
14
96-09-13, 09.44
TOOLS
Tools for saws 36 and 41
Tools for saws 40, 45, 51 and 55
3 mm; 4 mm; 5 mm
4 mm
8 mm; 10 mm
8 mm
502 50 33-01
502 50 33-01
505 26 79-12
40 > 910 1116
45 > 925 1168
50 > 925 0856
502 51 94-01
530 03 11-12
530 03 11-36
502 50 99-01
(55)
502 51 94-01
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
Eng, p 2-39
15
96-09-13, 09.45
15
TOOLS
Tools for saws 42, 242 and 246
3 mm; 4 mm
3 mm; 4 mm
8 mm
8 mm
502 50 33-01
502 50 33-01
*compl 502 51 49-02
*compl 502 51
49-02
502 51 49-01*
502 51 49-01*
*502 51 54-01
*502 51 54-01
502 50 26-01*
502 50 26-01*
502 50 99-01
502 50 99-01
502 70 03-01
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
compl 502 50 38-01

502 50 45-01
502 50 72-01
502 50 46-01
502 50 71-01
502 50 45-01
502 50 72-01
502 50 46-01
502 50 71-01
16 English
Eng, p 2-39
16
96-09-13, 09.46
TOOLS
3 mm; 4 mm; 3/16"

3 mm; 4 mm; 3/16"
8 mm
502 71 36-01 (4 mm)
8 mm
502 71 36-01 (4 mm)
502 50 33-01
502 50 33-01
*compl 502 51 49-02
*compl 502 51 49-02
502 51 49-01*
502 51 49-01*
*502 51 54-01
*502 51 54-01
502 50 26-01*
502 50 26-01*
502 70 03-01
compl 502 50 31-01
504 90 90-01
502 51 61-01
502 51 61-01
504 90 90-01
502 50 82-01
502 51 69-01
(268)
502 50 30-04
502 50 30-08
502 50 53-01
502 50 52-01
502 50 66-02
502 50 67-01
502 51 00-02
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 46-01
502 50 48-01
502 50 81-01
502 50 20-01
English
Eng, p 2-39
17
96-09-13, 09.47
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 04-01
(394)
502 71 40-01
(3120)
502 52 01-01 (394)

502 71 38-01 (3120)
502 71 39-01 (394)
18 English
Eng, p 2-39
18
96-09-13, 09.48
TOOLS
List of tools
Order number
Designation
Order number
502 50 06-01
502 50 16-01
502 50 18-01
502 50 19-01
502 50 20-01
Pliers
Allen key
Allen key
Allen key
Assembly tool
502 51 49-01
502 51 49-02
502 51 50-01
502 51 54-01
502 51 61-01
Puller
Puller
Socket
Bolt set
Dismantling tool, crankcase
502 50 22-01
502 50 23-01
502 50 26-01
502 50 30-04
502 50 30-08
Socket
Socket
Puller
Assembly tool
Assembly tool
502 51 69-01
502 51 69-01
502 51 94-01
502 52 01-01
502 52 04-01
Assembly mandrel
Feeler gauges
Assembly mandrel
Cover plate
Spacer
502 50 30-09
502 50 30-10
502 50 31-01
502 50 33-01
502 50 37-01
Assembly tool
Assembly tool
Puller
Piston stop
Vacuum gauge
502 54 03-01
502 70 09-01
502 71 13-01
502 71 14-01
502 71 36-01
Spacer
Pump blower
Test spark plug
Tachometer
Allen key
502 50 38-01
502 50 45-01
502 50 46-01
502 50 47-01
502 50 48-01
Pressure gauge
Extended socket
Extended socket
Cover plate
Cover plate
502 71 38-01
502 71 39-01
502 71 40-01
504 90 29-02
504 90 90-01
Cover plate
Cover plate
Spacer
Cover plate
Puller
502 50 52-01
502 50 57-01
502 50 64-01
502 50 66-02
502 50 67-01
Assembly socket
Allen key
Allen key
U-key
U-key
504 98 26-01
505 26 79-12
505 38 18-17
Silicone rubber
Assembly mandrel
Puller
502 50 70-01
502 50 71-01
502 50 72-01
502 50 79-01
502 50 81-01
Assembly tool, piston

Cover plate
Cover plate
Assembly mandrel
Cover plate
502 50 82-01
502 50 83-01
502 50 86-01
502 50 87-01
502 50 88-01
Assembly mandrel
Hook, tank valve
Allen key
Allen key
Allen key
502 50 99-01
502 51 00-02
502 51 02-01
502 51 32-01
502 51 34-02
Puller sleeve
U-key
Assembly fixture
Assembly sleeve
Feeler gauge
Designation
English
Eng, p 2-39
19
96-09-13, 09.48
19
SERVICE DATA
Saws 36 and 41
10
15
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
Eng, p 2-39
20
96-09-13, 09.48
SERVICE DATA
15
28
3
English
Eng, p 2-39
21
96-09-13, 09.48
21
SERVICE DATA
Saws 42, 242 and 246
5
8-10
7-8
242
4-5
42 246
15
5
10
242
42 246
Character key

22 English
Eng, p 2-39
22
96-09-13, 09.49
SERVICE DATA
20
9
13
2
2
4
28
6
2
English
Eng, p 2-39
23
96-09-13, 09.49
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
Eng, p 2-39
24
96-09-13, 09.49
SERVICE DATA
2-3
3-4
2-3
2-3
20
2-3
2-3
2-3
8-10
2-3
3-4
2-3
25-30
2-3
English
Eng, p 2-39
25
96-09-13, 09.49
25
SERVICE DATA
Saws 51 and 55
4-5
7-8
15
30-40
6-8
3-4
3-4
1,5-2
8-10
Character key
3-4

26 English
Eng, p 2-39
26
96-09-13, 09.50
SERVICE DATA
3-4
3-4
3-4
15
8-10
12-14
3-5
1-2
25
3-4
3-4
Eng, p 2-39
27
96-09-13, 09.50
English
27
SERVICE DATA
Saws 254 and 257
254
10
257
5
10
15
35
Character key


28 English
Eng, p 2-39
28
96-09-13, 09.50
SERVICE DATA
3
4
20
10
13
254
4
9
28
English
Eng, p 2-39
29
96-09-13, 09.54
29
SERVICE DATA
Saw 262
5
4
6
10
15
4
35
Character key


30 English
Eng, p 2-39
30
96-09-13, 09.54
SERVICE DATA
2
4
20
13
5
4
4
3
4
9
28
5
English
Eng, p 2-39
31
96-09-13, 09.54
31
SERVICE DATA
Saws 61, 268 and 272
2
5
10
6
6
10
15
6
35
61
35
268 272
1
4
8
Character key
Numbers by components that are

bolted refer to the tightening torque in Nm.
3
32 English
Eng, p 2-39
32
96-09-13, 09.55
SERVICE DATA
3
1
3
61
1
3
1
15
10
268 272
14
5
4
6
6
4
272
3
28
4
9
English
Eng, p 2-39
33
96-09-13, 09.56
33
SERVICE DATA
Saws 281 and 288
13
4
6
15
35
Character key

34 English
Eng, p 2-39
34
96-09-13, 09.56
SERVICE DATA
4
3
6
20
11
17
7
7
35
7
English
Eng, p 2-39
35
96-09-13, 09.57
35
SERVICE DATA
Saw 394
10-12
15
6-8
2-4
7-9
Character key
Numbers by components that are
bolted refer to the tightening torque
in Nm.
36 English
Eng, p 2-39
36
96-09-13, 09.57
SERVICE DATA
5-6
20-22,5
10-12
3-5
12-14
3-5
5-6
4-5
30-40
2-3
English
Eng, p 2-39
37
96-09-13, 09.57
37
SERVICE DATA
Saw 3120
5
4
12
15
38
8
7
5
7
Character key

38 English
Eng, p 2-39
38
96-09-13, 09.57
SERVICE DATA
3
5
7
17
20
12
10
12
8
6
3
40
4
9
4
English
Eng, p 2-39
39
96-09-13, 09.58
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.
Idling (low rpm) (cont.)
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
Carburettor
leaking fuel
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
Flooding when
the engine is not
running
Worn needle valve

Idling (low rpm)

Will not idle
Idling too rich
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
Idles when L-screw

closed

Leaking control diaphragm/
cover plate
Worn throttle lever
Faulty diffuser jet
Idling uneven
Fuel filter blocked

Fuel line blocked
Leaking manifold
Worn throttle valve shaft
Loose throttle valve screw
Worn throttle valve
Leak in throttle system (air or
fuel)
Control diaphragm centre knob
is worn
Hole in diaphragm
cover plate
Crankcase leaking
L-screw requires
constant adjustment
Fuel line blocked

Control system (air or fuel)
cover plate
Faulty diffuser jet
Crankcase leaking
Too much fuel at idling
Adjust L-screw
Worn throttle lever
cover plate
40 English
Eng, p 40-82
40
96-09-13, 10.14

Control system damaged
Worn needle valve
cover plate
Control system incorrectly
assembled
TROUBLE SHOOTING
Acceleration and retardation
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
pump side
Faulty pump diaphragm
Leaking manifold
Control system set too low
Control system damaged
assembled
Leaking control diaphragm/cover
Blocked silencer
Low power
Adjust H-screw
Blocked fuel filter
pump side
Blocked air filter
fuel)
assembled
Loose diaphragm
Hole in diaphragm
Blocked fuel tank breather
Blocked fuel filter
Fuel line blocked
pump side
Leaking manifold
bolts
Control system set too low
fuel)
assembled
Loose diaphragm
Hole in diaphragm
Will not
four-stroke
Does not accelerate
Adjust L-screw
Adjust H-screw
Blocked air filter
Blocked fuel filter
Fuel line blocked
pump side
Leaking manifold
Throttle set too low
assembled
Faulty diffuser jet
Blocked silencer
Motor stalls when

throttle released
Adjust L-screw
Adjust H-screw
Faulty diffuser jet
Over rich acceleration
Adjust L-screw
Adjust H-screw
Blocked air filter
Faulty diffuser jet
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.
2.
Pressure testing the crankcase and cylinder.

See page 114.
3.
Pressure testing the decompression valve.

See page 114.
4.
Checking the operation of the chain brake.

See page 47.
English
Eng, p 40-82
41
96-09-13, 10.14
41
SAFETY EQUIPMENT
Chain brake
A
Dismantling
Dismantle the clutch cover and clean. See
the operating instructions.
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
Remove the cover on the chain brake spring.

The cover has 4 or 5 screws.
3120
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
WARNING!
If the brake is not 'on', the spring
can fly out resulting in personal
injury.
Continues on next page.
3120 continues on next page.
42 English
Eng, p 40-82
42
96-09-13, 10.14
SAFETY EQUIPMENT
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.
English
Eng, p 40-82
43
96-09-13, 10.14
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.
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
Eng, p 40-82
44
96-09-13, 10.14
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 cover over the spring.
3120
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.
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.
English
Eng, p 40-82
45
96-09-13, 10.14
45
SAFETY EQUIPMENT
3120
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
Eng, p 40-82
46
96-09-13, 10.15
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.
English
Eng, p 40-82
47
96-09-13, 10.15
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
Eng, p 40-82
48
96-09-13, 10.15
SAFETY EQUIPMENT
Muffler
Dismantling
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.
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.
English
Eng, p 40-82
49
96-09-13, 10.15
49
SAFETY EQUIPMENT
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
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.
Assemble the muffler and fit to the

cylinder. Tightening torque, see page
20.
Saws 36 and 41
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.
Other saws
Tighten all bolts using the tightening

torque set out in the "Service data".
B
!
242 Cat
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
Only specially treated bolts may be used on

the catalytic converter (high temperature).
See spare parts catalogue.
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
Eng, p 40-82
50
96-09-13, 10.16
SAFETY EQUIPMENT
Stop switch
A
Dismantling
Remove the earth screw (A) and cable (B).
Press the switch's securing tabs (C) towards

each other and push out the switch.
B

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.
English
Eng, p 40-82
51
96-09-13, 10.16
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.
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
Saw 394
Turn the throttle lock as

shown in the figure, and lift
it out with the spring from
the cut-out in the handle.
Saws 61, 268, 268K,

272XP, 272K, 272S,
281XP, 288XP and
394.
Saws 61, 268, 272XP, 272K,

272S, 281XP and 288XP.
Slide the throttle lock and

remove it forwards as
shown in the figure.
Saw 3120.
See continuation on next
page.
Saws 36, 41, 42, 55,

242XP, 246, 51,
254XP, 257 and
262XP.
Carefully prise up the lock

from the slot and remove.
52 English
Eng, p 40-82
52
96-09-13, 10.16
SAFETY EQUIPMENT
Saws 61, 268, 268K, 272XP, 272K, 272S,
281XP, 288XP and 394.
Dismantle the throttle pin (B) by using a

punch.
B
Saws 36, 41, 42, 55, 242XP, 246, 51, 254XP,

257 and 262XP.
Remove the rubber element (A). Slide out

the throttle pin (B) and lift out the throttle arm
and spring.
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.
English
Eng, p 40-82
53
96-09-13, 10.16
53
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
Eng, p 40-82
54
96-09-13, 10.17
SAFETY EQUIPMENT
Assembly
Saws 36, 40, 41, 45, 42,
242XP, 246, 51, 55,
254XP, 257 and 262XP.
Other saws.
WARNING!
1. The liquid and its vapours
are poisonous.
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.
English
Eng, p 40-82
55
96-09-13, 10.17
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
Eng, p 40-82
56
96-09-13, 10.17
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!
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!
If the spring is to be replaced, remove the old

spring from the starter pulley. Some saws
have a protective plate over the spring.
English
Eng, p 40-82
57
96-09-13, 10.21
57
STARTER
WARNING!

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.
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
Eng, p 40-82
58
96-09-13, 10.21
STARTER
Assembly
WARNING!
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.
English
Eng, p 40-82
59
96-09-13, 10.21
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
Eng, p 40-82
60
96-09-13, 10.21
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.
English
Eng, p 40-82
61
96-09-13, 10.21
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
Eng, p 40-82
62
96-09-13, 10.22
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.
English
Eng, p 40-82
63
96-09-13, 10.22
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.
Fit the ignition coil, which is located next to

the carburettor and connect the cables.
Fit the starter and cylinder cover.
Other saws.
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
Eng, p 40-82
64
96-09-13, 10.23
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.
English
Eng, p 40-82
65
96-09-13, 10.23
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
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.
Checking the power switch
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
Eng, p 40-82
66
96-09-13, 10.25
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.
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.
Remove the springs using a

screwdriver.
Then remove the clutch
shoes.
Saws with three C-springs.
Remove the spring by first

lifting a shoe using a suitable
spacer (A).
Then remove the clutch
shoes.
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.
English
Eng, p 40-82
67
96-09-13, 10.26
67
CENTRIFUGAL CLUTCH
Clean all parts and inspect the following:
Clutch
shoes
without chamfers.
That measurement A is not below 1 mm.
Clutch shoes
with chamfers.
That measurement B is not under 1 mm.
A
B
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
Eng, p 40-82
68
96-09-13, 10.26
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.
Locate the clutch shoes on

the hub and fit the springs
with the help of pliers.
NOTE! The clutch

springs should not be
opened out more than
necessary. Risk of
deformation.
Saws with three C-springs.
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.
English
Eng, p 40-82
69
96-09-13, 10.26
69
LUBRICATION SYSTEM
Dismantling
Dismantle the following parts:
Saws 36, 40, 41, 45, 51 and 55. See page 72
Starter. See the operating instructions

Centrifugal clutch. See page 67.
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).
D
2. Undo screw (C).

3. Lever out the pump piston (D) and
plastic plug (E) using a screwdriver.
B
A
4. Remove the seal (F).
70 English
Eng, p 40-82
70
96-09-13, 10.27
LUBRICATION SYSTEM
Saws 61, 268, 272XP.
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.

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
English
Eng, p 40-82
71
96-09-13, 10.27
71
LUBRICATION SYSTEM
Saw 394.
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.

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
Eng, p 40-82
72
96-09-13, 10.31
LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.
Dismantle the chain guide plates as shown

in respective diagrams below.
36/41
Saws 36, 40, 41 and 45.
Undo the two bolts and lift off the pump

and the upper seal.
40/45
51/55
Saws 51 and 55.
Lift off the pump and the upper seal.
Take the pump apart as shown in the exploded view on

the next page.
English
Eng, p 40-82
73
96-09-13, 10.31
73
LUBRICATION SYSTEM
G
B C
40/45
36/41
A.
B.
C.
D.
E.
F.
G.
50/51
74 English
Eng, p 40-82
74
96-09-13, 10.31
Lower seal.
Pump cylinder.
Upper seal.
Chain guide plate.
Pump housing.
Pump piston.
Worm gear.
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.
English
Eng, p 40-82
75
96-09-13, 10.31
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
Eng, p 40-82
76
96-09-13, 10.32
LUBRICATION SYSTEM
Assembling the worm gear
Screw the worm gear into the dismantling
tool and press the worm gear onto the
crankshaft until it bottoms against the
collar.
On those saws where the oil pump worm

gear is pressed on the crankshaft.
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
See continuation, page 80.
Saws 61, 268, 272XP.
F
1.
2.
3.
4.
5.
6.
7.
8.
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
A
H
English
Eng, p 40-82
77
96-09-13, 10.33
77
LUBRICATION SYSTEM
Saws 281XP and 288 XP.
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.

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).
78 English
Eng, p 40-82
78
96-09-13, 10.33
LUBRICATION SYSTEM
Saw 3120.

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
Fit the wire for manual oil supply.
English
Eng, p 40-82
79
96-09-13, 10.33
79
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.
80 English
Eng, p 40-82
80
96-09-13, 10.34
LUBRICATION SYSTEM
Saws 36, 40, 41, 45, 51 and 55.

A.
B.
C.
D.
E.
F.
G.

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.
Lower seal.
Pump cylinder.
Upper seal.
Chain guide plate.
Pump housing.
Pump piston.
Worm gear
G
B C
40/45
36/41
50/51
Saws 36, 40, 41 and 45, see

continuation on the next page.
Saws 51 and 55, see continuation

on the next page.
English
Eng, p 40-82
81
96-09-13, 10.34
81
LUBRICATION SYSTEM
Saws 36, 40, 41 and 45.
Saws 51 and 55.
Fit the oil pump in the crankcase and fit

the upper seal.
Fit the oil pump in the crankcase, tighten

the two bolts 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
Eng, p 40-82
82
96-09-13, 10.34
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.
WARNING!
The fuel used in the chain saw poses
the following hazards:
1. The liquid and its vapours are
poisonous.
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.
English
Eng, p 83-124
83
96-09-13, 11.08
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).
In the full throttle mode both valves are

open and fuel is supplied through all three
diffuser jets (E, F and G).
84 English
Eng, p 83-124
84
96-09-13, 11.08
CARBURETTOR
Dismantling
WARNING!
poisonous.
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.
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.
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.
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
Eng, p 83-124
85
96-09-13, 11.09
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.
F
G
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.
H
B
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.
Tillotson HS 255 B
2. Undo the screw (H) and take out
the needle valve (C) with lever
arm, shaft and spring.
E
F
G

4. Using a needle or the like carefully
remove the fuel screen (D).

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
8. Remove the speed governor (I). (Only

272K, 268K and 272S).
9. Remove the semi fixed jet (K). See page 85.
86 English
Eng, p 83-124
86
96-09-13, 11.09
CARBURETTOR
Tillotson HS 260 A

F
G
2. Undo the screw (H) and take out the

needle valve (C) with lever arm, shaft and
spring.

J
H

C
screws.
and springs.
B
A
Walbro HDA and HD
A
B

spring.
H
C
3. Remove the cover (E) over the pump

unit and carefully remove the gasket (F)
and the pump diaphragm (G).

D
screws.
G
6. Remove the plug (J). See page 85.
F
valves as well as the shafts, lever arms and
springs.
English
Eng, p 83-124
87
96-09-13, 11.09
87
CARBURETTOR
Walbro WJ

spring.
F
G
D

screws.
and springs.
H
B
A
Walbro WG


spring.
H
C
K


5. Unscrew the low speed jet screws.
D
and springs.
G
F

E
88 English
Eng, p 83-124
88
96-09-13, 11.09
CARBURETTOR
Walbro WT
E

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).
C
J

screws.
and springs.
8. Remove the semi fixed jet with diffuser

jet (K). See page 85.
ZAMA C1Q-EL1
A

spring.
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
English
Eng, p 83-124
89
96-09-13, 11.09
89
CARBURETTOR
WARNING!
poisonous.
Clean all components in petrol. Wear

gloves or skin protection cream.
WARNING!
Never direct the compressed air
jet towards the body. Air can be
forced into the blood stream and
can cause fatality.
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.
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.
90 English
Eng, p 83-124
90
96-09-13, 11.09
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!
1. The fluid and its vapours are
poisonous.
Semi fixed jet/fixed jet
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.
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.
English
Eng, p 83-124
91
96-09-13, 11.10
91
CARBURETTOR
Tillotson HS 228 B
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.
F
G
D
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.
J
C
H
B
A
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.
92 English
Eng, p 83-124
92
96-09-13, 11.10
CARBURETTOR
Tillotson HS 255 B
D

particles of dirt can cause operating problems.
Lubricate the shaft bearings using a light
oil.
F
G
I
J
H
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.
C
H
B
A

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.
English
Eng, p 83-124
93
96-09-13, 11.10
93
CARBURETTOR
Tillotson HS 260 A
E

problems.
oil.
F
G
D
J
H

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.
C
H
B
A

10. Carry out a pressure test. See page 100.
94 English
Eng, p 83-124
94
96-09-13, 11.11
CARBURETTOR
Walbro HDA och HD
A
B

H
C

Lubricate the shaft bearings using a
light oil.

needle tips.
G
F
E

English
Eng, p 83-124
95
96-09-13, 11.11
95
CARBURETTOR
Walbro WJ
E
F

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.
G
D

needle tips.
K
H
B
A

7. Fit the needle valve (C) with lever arm, shaft
and spring and tighten screw (H).
arm can be bent if necessary to achieve the
correct settings.
96 English
Eng, p 83-124
96
96-09-13, 11.11
CARBURETTOR
Walbro WG
A
B

H
C

Lubricate the shaft bearings using a light oil.
K
J

3. Fit the fixed jet (K). See page 91.
needle tips.
D
G
F
E

correct settings.
English
Eng, p 83-124
97
96-09-13, 11.11
97
CARBURETTOR
Walbro WT
E
problems.
G
Lubricate the shaft bearings using a light oil.
C
J
needle tips.
A
5. Fit the fuel screen (D) by using the handle of
a small screwdriver.
correct settings.
98 English
Eng, p 83-124
98
96-09-13, 11.11
CARBURETTOR
ZAMA C1Q-EL1
problems.
A
B

oil.
needle tips.
C
K
D
G

F
E

English
Eng, p 83-124
99
96-09-13, 11.11
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.
WARNING!
poisonous.
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
Fault with
Diffuser jets
Needle valve
Leakage on the
pulse tube
Pump diaphragm
Ventilation hole
above the metering unit
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
Eng, p 83-124
100
96-09-13, 11.11
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.
English
Eng, p 83-124
101
96-09-13, 11.15
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
Eng, p 83-124
102
96-09-13, 11.15
TANK UNIT
Dismantling
Empty the tank and dismantle the cylinder
cover as well as the bar and chain.
WARNING!
poisonous.
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.

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.
English
Eng, p 83-124
103
96-09-13, 11.15
103
TANK UNIT
A
B
C
D
E
L
K
J
I
F
Saw
Bolts placed at
36
40
41
A, D, F, K
Has no tank unit
A, D, F, K
257
262XP
268
A, D, F, L
A, D, F, L
A, C, D, F, G, K
42
45
51
A, D (under a cover) F, G, L
Has no tank unit
A, D, F, L (all under covers)
268K
272XP
272K
A, C, D, F, G, K
A, C, D, F, G, K
A, C, D, F, G, K
55
61
242XP
A, D, F, L (all under covers)

A, C, D, F, G, K
272S
281XP
288XP
A, C, D, F, G, K
A, C, D, F, G, K
A, C, D, F, G, K
246
254XP
A, D, F, L
394XP
B, E, G, I, H
3120XP C, D, F, I, J
Saw
Bolts placed at
104 English
Eng, p 83-124
104
96-09-13, 11.15
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.
Make the handle heater connections if necessary.
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.
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.
English
Eng, p 83-124
105
96-09-13, 11.15
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
Release the catch on the plastic key.
Slide off the spring and its holder.
Saws 40, 45 and 3120
Other saws
Remove the rubber element using respective tools as shown in the figure
below.
Remove the spring element using an allen

key as shown below.
106 English
Eng, p 83-124
106
96-09-13, 11.15
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
Slide in the spring and its holder.
Saws 40, 45 and 3120
Other saws
Fit the rubber element using the tools

Fit the spring element using an allen key as

English
Eng, p 83-124
107
96-09-13, 11.15
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
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.
Dismantle the tank unit.

See page 102.
Saws 40 and 45.
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.
108 English
Eng, p 83-124
108
96-09-13, 11.16
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.
Max 1 mm
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.
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).
English
Eng, p 83-124
109
96-09-13, 11.16
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
Eng, p 83-124
110
96-09-13, 11.16
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.
English
Eng, p 83-124
111
96-09-13, 12.56
111
PISTON AND CYLINDER

Other saws
Saws 36, 40, 41 and 45.
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).
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
Eng, p 83-124
112
96-09-13, 12.57
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
English
Eng, p 83-124
113
96-09-13, 12.59
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.
Saws 36, 40, 41 and 45. See next page.
Saw 394.
D.
E.
F.
G.
H.
I.

Oil pump. See page 70.
Carburettor.
Muffler. See page 49.
Piston and cylinder. See page 108.
Tank unit. See page 103.
Other saws
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
Eng, p 83-124
114
96-09-13, 13.02

Press out the crankshaft by using tool
502 51 61-01.
If necessary remove the crankshaft
bearing from the crankcase.
Proceed as follows:
WARNING!
The crankcase halves can be
hot. Risk of burns. Wear protective gloves.
Remove all rubber and plastic components

from the crankcase halves.
Saws 36 and 41.
Saws 40 and 45.
Split the shaft support and

dismantle the 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.
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
Eng, p 83-124
115
96-09-13, 13.03
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
Eng, p 83-124
116
96-09-13, 11.34

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
Eng, p 83-124
117
96-09-13, 11.34
117

Saw 40 and 45.
See page 120.
Grease and fit a new crankcase gasket (A).

Check that the guide pin (B) is in position and
fit the other crankcase half.
Other saws.
NOTE!
Ensure that the connecting rod does
not jam against the crankcase when
the crankcase and crankshaft are
assembled.
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
Eng, p 83-124
118
96-09-13, 11.35

Other saws.
Saw 40 and 45.
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.

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.
English
Eng, p 83-124
119
96-09-13, 11.38
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
Eng, p 83-124
120
96-09-13, 11.38

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
Eng, p 83-124
121
96-09-13, 11.38
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
Eng, p 83-124
122
96-09-13, 11.39

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.
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
English
Eng, p 83-124
123
96-09-13, 11.39
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

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

51, 55
394
1 mm
0.5 mm
254, 257, 262 1.5 mm above the

crankcase plane.
1.5 mm
124 English
Eng, p 83-124
124
96-09-13, 11.40

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Husqvarna Chain Saws

This workshop manual applies to the engine

The descriptive sections in this workshop manual

Dismantling and reassembly of the entire

This workshop manual can be used in two different

Repair of a specific sub-assembly

Refer to page 57, which deals with the

Work forwards through the manual and

Repair of a specific sub-assembly

Refer to the page referring to the relevant subassembly.

Carry out the steps: Dismantling

Return to the Starter on page 58 and

Work forward through the manual and

Order or collect all the required spare

In order to Assemble the chain saw,

Refer to pages 117-120 which deals with

Refer to pages 111-112 which deals with

Refer to pages 107 which deals with the

Refer to page 105 which deals with the

Continue to work backwards through the

Do not use the saw until it has been

The chain saw is type approved with

After testing, do not touch the

Inadequate chain lubrication can result in

Spark plug gap

Drive link gauge

1.5/ .058 / 1.3/ .0501)

From May 1996

Fuel tank volume

Oil pump capacity

Oil tank volume

Automatic oil pump

Weight without bar and chain

Weight with bar and chain

Spark plug gap

Drive link gauge

1.5/ .058 / 1.3/ .050 1)

1.5/ .058 / 1.3/ .050 1)

From May 1996

Fuel tank volume

Oil pump capacity

Oil tank volume

Automatic oil pump

Weight without bar and chain

Weight with bar and chain

Spark plug gap

WALBRO HDA 120

Drive link gauge

Fuel tank volume

Oil pump capacity

Weight without chain and bar

Oil tank volume

Weight with chain and bar

Automatic oil pump

Spark plug gap

Drive link gauge

Oil pump capacity

Oil tank volume

Automatic oil pump