101
Husqvarna Chain Saws
Workshop Manual
LIST OF CONTENTS
Air filter
Tank unit
Anti-vibration system
Safety
Updates
INTRODUCTION
General
INTRODUCTION
Repair of a specific sub-assembly
Dismantling and reassembly of the entire chain saw
Special instructions
SAFETY REGULATIONS
General Instructions
TECHNICAL DATA
6 - English
TECHNICAL DATA
TECHNICAL DATA
8 - English
TECHNICAL DATA
TECHNICAL DATA
10 - English
TECHNICAL DATA
TECHNICAL DATA
12 - English
TECHNICAL DATA
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 88-01 5 mm
Tools for saws 36 and
Tools for saws 40, 45, 51 and
TOOLS
compl 502 50
Tools for saws 42, 242 and
Tools for saws 254, 257 and
TOOLS
compl 502 51
Tools for saws 61, 268 and
Tools for saws 281 and
TOOLS
compl 502 51
Tools for saws 394 and
TOOLS
3 mm 4 mm 5 mm 3/16 8 mm 10 mm 502 50
compl 502 51
List of tools
TOOLS
Order number
Designation
SERVICE DATA Saws 36 and
Character key
SERVICE DATA
English
22 - English
SERVICE DATA Saws 42, 242 and
Character key
SERVICE DATA
English
Saws 40 and
SERVICE DATA
Character key
24 - English
SERVICE DATA
English
Saws 51 and
SERVICE DATA
Character key
26 - English
SERVICE DATA
3-4English
SERVICE DATA Saws 254 and
5254
Character key
28 - English
SERVICE DATA
English
30 - English
SERVICE DATA
Character key
SERVICE DATA
English
32 - English
SERVICE DATA Saws 61, 268 and
Character key
SERVICE DATA
English
34 - English
SERVICE DATA Saws 281 and
Character key
SERVICE DATA
English
36 - English
SERVICE DATA
Character key
SERVICE DATA
20-22,5 10-12 12-14
30-40 2-3
3-5 5-6
38 - English
SERVICE DATA Saw
Character key
SERVICE DATA
English
TROUBLE SHOOTING Trouble shooting schematic
Starting
Idling low rpm
Idling low rpm cont
TROUBLE SHOOTING
Trouble shooting methods
High rpm
Acceleration and retardation
SAFETY EQUIPMENT
Chain brake
Dismantling
Wear protective glasses
SAFETY EQUIPMENT
Cleaning and Inspection
Assembly
SAFETY EQUIPMENT
44 - English
SAFETY EQUIPMENT
SAFETY EQUIPMENT
46 - English
The engine should not be running during the test
Checking brake operation
SAFETY EQUIPMENT
Replacing
SAFETY EQUIPMENT Chain catcher
Description
Muffler
SAFETY EQUIPMENT
Dismantling
Do not touch the muffler until it has cooled. Risk of burns
SAFETY EQUIPMENT
Cleaning and Inspection
Assembly
when working on a catalytic converterWARNING
SAFETY EQUIPMENT Stop switch
Cleaning and Inspection
Assembly
Dismantling
Throttle lock
SAFETY EQUIPMENT
Dismantling
The fuel used in the chain saw poses the following hazards
SAFETY EQUIPMENT
Cleaning and inspection
SAFETY EQUIPMENT
Clean all parts
Check that the springs, where fitted, are
SAFETY EQUIPMENT
Assembly
The fuel used in the chain saw poses the following hazards
1. The liquid and its vapours are poisonous
SAFETY EQUIPMENT
56 - English
Wear protective glasses
STARTER
Dismantling
Changing the ferrule
Cleaning and Inspection
STARTER
Remove the parts of the old ferrule
Assembly
STARTER
60 - English
STARTER
Check the cord tension
ELECTRICAL SYSTEM Ignition system
Dismantling
ELECTRICAL SYSTEM
Cleaning and Inspection
Assembly
Clean all parts, especially the flywheel and shaft taper
ELECTRICAL SYSTEM
Stop switch
Fitting the spark plug cover
ELECTRICAL SYSTEM
64 - English
Trouble shooting
Handle heating
ELECTRICAL SYSTEM
Description
Checking the power switch
ELECTRICAL SYSTEM
Checking the generator
Checking the heat loops in the rear handles
CENTRIFUGAL CLUTCH
Dismantling
CENTRIFUGAL CLUTCH
Cleaning and Inspection
Clean all parts and inspect the following
NOTE! The bearing can also be greased later through the hole on the crankshaft
Assembly
CENTRIFUGAL CLUTCH
70 - English
LUBRICATION SYSTEM
Dismantling
LUBRICATION SYSTEM
LUBRICATION SYSTEM
72 - English
40/45
51/55
LUBRICATION SYSTEM
36/41
74 - English
LUBRICATION SYSTEM
40/45
Dismantling the oil pumps worm gear
LUBRICATION SYSTEM
First screw the tool onto the entire worm gear
Turn the screw until the worm gear is removed
LUBRICATION SYSTEM
Cleaning and Inspection
That the taper on the adjuster screw shows no signs of wear
LUBRICATION SYSTEM
Assembling the worm gear
Assembling the oil pump
LUBRICATION SYSTEM
78 - English
LUBRICATION SYSTEM
LUBRICATION SYSTEM
Saws 42, 61, 242, 246, 254, 257, 262, 268, 272, 281, 288, 394 and
36/41
50/51
LUBRICATION SYSTEM
40/45
LUBRICATION SYSTEM
40/45
51/55
82 - English
CARBURETTOR
Description
Design
The fuel used in the chain saw poses the following hazards
CARBURETTOR
Operation
CARBURETTOR
Dismantling
The fuel used in the chain saw poses the following hazards
1. The liquid and its vapours are poisonous
Tillotson HS 228 B
Tillotson HS 255 B
CARBURETTOR
86 - English
CARBURETTOR
Tillotson HS 260 A
Walbro HDA and HD
Walbro WJ
Walbro WG
CARBURETTOR
88 - English
CARBURETTOR
Walbro WT
ZAMA C1Q-EL1
Cleaning and Inspection
CARBURETTOR
The fuel used in the chain saw poses the following hazards
1. The liquid and its vapours are poisonous
Assembly
CARBURETTOR
Plugs
The fuel used in the chain saw poses the following hazards
92 - English
CARBURETTOR
Tillotson HS 228 B
CARBURETTOR
Tillotson HS 255 B
94 - English
CARBURETTOR
Tillotson HS 260 A
Walbro HDA och HD
CARBURETTOR
96 - English
CARBURETTOR
Walbro WJ
CARBURETTOR
Walbro WG
98 - English
CARBURETTOR
Walbro WT
CARBURETTOR
ZAMA C1Q-EL1
Pressure testing
Refitting onto chain saw
CARBURETTOR
The fuel used in the chain saw poses the following hazards
AIR FILTER
268K, 272K and 272S
Prefilter
Compressed air at a high pressure can damage the foam
102 - English
AIR FILTER
Main filter
TANK UNIT
Cleaning and Inspection
Dismantling
The fuel used in the chain saw poses the following hazards
Bolts placed at
TANK UNIT
262XP
268K
Ensure that the fuel pipe and throttle cable are not damaged
Assembly
TANK UNIT
ANTI-VIBRATION SYSTEM
Description
Dismantling
106 - English
Assembly
ANTI-VIBRATION SYSTEM
108 - English
PISTON AND CYLINDER
Dismantling
1. The piston crown 2. The top of the cylinder bore
Cleaning and Inspection
PISTON AND CYLINDER
Faults and causes
PISTON AND CYLINDER
Assembly
PISTON AND CYLINDER
PISTON AND CYLINDER
112 - English
Pressure testing
PISTON AND CYLINDER
Decompression valve
Crankcase and cylinder
Ensure that no dirt or foreign particles enter the bearings
CRANKCASE AND CRANKSHAFT
Dismantling
CRANKCASE AND CRANKSHAFT
116 - English
Cleaning and Inspection
CRANKCASE AND CRANKSHAFT
Ensure that dirt and foreign particles do not enter the bearing
Assembly
CRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
118 - English
CRANKCASE AND CRANKSHAFT
Ensure excess gasket material does not fall into the crankcase
120 - English
CRANKCASE AND CRANKSHAFT
Ensure that dirt and foreign particles do not enter the bearing
Bar bolts
CRANKCASE AND CRANKSHAFT
Dismantling
Changing the seals
CRANKCASE AND CRANKSHAFT
Assembly
CRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
3.5 mm
42, 242, 246 1 mm
3120