CS2255

CS 2255
Workshop manual 505 48 19-26
2 – English
 Workshop manual
Jonsered CS 2255

Contents
Introduction ........................................................... 4
Safety regulations ................................................ 5
General instructions ........................................... 5
Special instructions ............................................ 5
Special tools ......................................................... 6
Technical data ....................................................... 8
Carburettor .......................................................... 10
Carburettor ...................................................... 10
Carburettor - pressure testing .......................... 15
Carburettor - adjustment .................................. 16
Troubleshooting .................................................. 18
Repair instructions ............................................. 20
Chain brake ...................................................... 20
Silencer ............................................................ 22
Chain catcher ................................................... 22
Stop switch ....................................................... 23
Stop switch – resistance measurement............ 23
Choke control ................................................... 24
Throttle trigger .................................................. 25
Starter assembly .............................................. 26
Starter cord....................................................... 26
Recoil spring..................................................... 27
Ignition module – testing .................................. 28
Ignition module and flywheel ............................ 28
Centrifugal clutch.............................................. 30
Oil pump ........................................................... 31
Air intake system ............................................. 33
Fuel filter........................................................... 34
Fuel hose.......................................................... 34
Fuel tank........................................................... 34
Piston and cylinder ........................................... 35
Decompression valve – pressure testing ......... 36
Cylinder – pressure testing............................... 37
Crankshaft complete ........................................ 38
Crankshaft bearings ......................................... 38
Thread insert .................................................... 39
Guide bar bolts ................................................. 39

English – 3
 Introduction
Arrangement of the manual Troubleshooting
This workshop manual can be used in two different These pages describe the most common faults that
ways. affect a chainsaw. They are divided into four dif-
ferent groups with the most likely faults described
• To repair a specific sub-assembly on a chainsaw. first.
• To dismantle and reassemble a complete chain-
saw.
Repair instructions
Repairing a specific sub-assembly The section that describes how to repair the
If a specific sub-assembly on the chainsaw needs chainsaw consists of detailed, step-by-step in-
to be repaired: structions. It explains in detail the special tools,
lubricants and bolt torques that are needed when
1. Look up the page referring to the relevant sub- working on each component.
assembly.
2. Follow the instructions under the headings: This workshop manual covers the following
• Removal/Dismantling chainsaw models: CS 2255

• Cleaning and inspection

• Refitting/Reassembly

Dismantling and reassembling the entire chainsaw

If the entire chainsaw is to be dismantled, follow

the instructions under the heading “Removal/Dis-
mantling”.

Work through the manual and follow the instruc-

tions given in each section under the heading
“Removal/Dismantling”.

Then follow all the “Cleaning and inspection” ins-

tructions in each section.

Working from the back of the manual, follow all the

instructions under the headings “Refitting/Reas-
sembly” in reverse order.

Each of the sections covering removal/dismantling

and refitting/reassembly include the relevant lubri-
cation instructions and bolt torques for each stage
of repair.

Construction and function

This chapter gives a simple description of the
chainsaw carburettor and its various parts.

4 – English
 Safety regulations

Safety regulations
General instructions Special instructions
This workshop manual gives detailed instructions The fuel that is used in a chainsaw poses the fol-
on how to troubleshoot, repair and test a chainsaw. lowing hazards:
This section also describes the various safety
precautions that should be taken when carrying out • The fuel and its fumes are toxic.
repairs.
• May cause irritation to skin or eyes.
The workshop manual has been written for person- • May cause breathing difficulties.
nel who are assumed to have general experience • Highly flammable.
of repairing and servicing chainsaws.

Workshops where chainsaws are repaired must be When using compressed air the air jet should
equipped with safety equipment that meets local never be pointed at the body. Air can be forced into
regulations. the bloodstream and cause fatal injury.

No-one should carry out repairs on a chainsaw Wear ear protection when testing saws.
until they have read and understood the contents
of this workshop manual. After testing a saw do not touch the silencer until
it has cooled down. The silencer gets very hot and
Chainsaws are type-approved to meet the rele- you may burn yourself. Wear protective gloves
vant safety legislation, but this only applies when when working on the silencer.
the saw is fitted with the cutting equipment speci-
fied in the user’s manual. The fitting of any other The guide bar, chain and clutch cover (chain
equipment, or of accessories or parts that are not brake) must be fitted before the saw is started. If
approved by Jonsered, could mean that the saw not, the clutch may come loose and cause injury.
no longer meets these safety requirements and
the person who carried out the work may be held Poor chain lubrication can result in failure of the
responsible for its non-conformance. chain, which could cause serious or fatal injury.

In this workshop manual the following boxes indi- Take care to ensure that the spring inside the
cate where caution should be taken. starter assembly does not fly out and cause injury.
Wear eye protection. If the spring is under
compression when the pulley is removed it could
WARNING! fly out and cause injury.
The warning text warns of the risk
of personal injury if the instruc- Before removing the tensioning spring from the
tions are not followed. chain brake, ensure that the brake is in the on
position, otherwise the spring may fly out and
cause injury.

After completing the repair the chain brake must be

NOTE!
tested, see “Chain brake – reassembly \ Operating
The warning text warns of the risk of ma- test”.
terial damage if the instructions are not
followed. Always consider the fire risk. A chainsaw can
produce sparks that could start a fire.

Inspect the chain catcher and replace it if it is

damaged.

English – 5
Special tools

Special tools
1 2 3

4 5 6

7 8

9 10

6 – English
 Special tools

11 12a 12b

13 14 15b
15c

15a

16

Item Description Used for Order no.

1 Clutch tool Centrifugal clutch 502 54 16-01
2 Piston stop Locking the crankshaft 504 91 06-05
3 Fuel filter hook Withdrawing the fuel filter 502 50 83-01
4 Allen key For M5 bolts 502 50 18-01
5 Pressure tester Pressure testing cylinder 503 84 40-02
6 Feeler gauge Adjusting ignition module 502 51 34-02
7 Assembly fixture Assembling chain saw 502 51 02-01
8 Pressure gauge Pressurisation during testing 531 03 06-23
9 Test spark plug Checking the ignition module 502 71 13-01
10 Rev counter Adjusting carburettor 502 71 14-01
11 Assembly pliers Fitting spark plug guard 502 50 06-01
12a Cover plate, exhaust Sealing the exhaust port 502 54 11-02
12b Cover plates, inlet Sealing the intake manifold 502 52 48-02
13 Assembly tool Assembling spring, chain brake 502 50 67-01
14 Puller Pulling bearing of crankshaft 504 90 90-01
15a Sleeve Fitting crankshaft 502 50 30-18
15b Shaft extension Flywheel side 502 50 30-18
15c Shaft extension Cluch side 502 50 30-18
16 Punch Dismantling the flywheel 502 51 94-01

English – 7
Technical data

Technical data

Displacement Cylinder bore Stroke Max power/speed

cm3/cubic inches Ø mm/Ø inches mm/inches kW/hp/rpm

CS 2255: 55,5 / 3,38 47 / 1,85 32 / 1,28 2,6 / 3,5 / 9 000

Spark plug gap Ignition system Air gap Carburettor type

mm/inches mm/inches

CS 2255: 0,5 / 0,02 SEM CD 0,3 / 0,012 Walbro WTEA

Effective cutting length Chain speed at Chain pitch Drive link

cm/inches max power – revs mm/inches mm/inches
m/s – rpm

CS 2255: 31-50 / 13-20 20,0 / 9 000 8,25 / 0,325 - 9,52 / 3/8 1,3 / 0,050 - 1,5 / 0,058

8 – English
 Technical data

rpm

Idling speed Engagement speed Spark plug

rpm rpm

CS 2255: 2 700 3 800 NGK BPMR 7A

Champion RCJ 7Y

GAS OIL

Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump
Litres/US pints 8,500 rpm, Litres/US pints
ml/min

CS 2255: 0,44 / 0,93 9 0,32 / 0,68 Yes

Weight without Weight with

bar and chain bar and chain
kg / lbs kg / lbs

CS 2255: 5,8 / 12,8 6,6 / 14,5

English – 9
Service data

Service data
1,5Nm

1,5Nm
1,5Nm

1,5Nm

15Nm 19mm

6Nm 4mm
13Nm 13mm

2,5Nm 4mm
13Nm 5mm

14Nm 5mm

20Nm

2Nm

28Nm 13mm

Character key 5Nm 4mm

The numbers by bolted components represent
the tightening torque in Nm. 8Nm 4mm
▲ = Lubricate using two-stroke oil.
■ = Lubricate using engine oil.
● = Lubricate using grease.
❑ = Glued using 2 component adhesive.
❍ = Sealed using silicone.

10 – English
 Service data

3Nm

4Nm 4mm

3Nm 4mm

5Nm 4mm

4Nm 4mm
4Nm 4mm

4Nm 4mm

9Nm 4mm

4Nm 4mm

9Nm 4mm
2,5Nm 4mm

3Nm 4mm

English – 11
Carburettor

Carburettor
Carburettor The mixing venturi (B) houses the choke, throttle
valve and diffuser jets. Here air is mixed with the
WARNING! fuel to give a fuel/air mixture that can be ignited by
The fuel used in the chainsaw has the ignition spark.
the following hazardous properties:
1. The fluid and its fumes are
poisonous.
2. Can cause skin irritation.
3. Is highly inflammable.

Description
The drawings accompanying this description do B
not correspond with the carburettor on the chain-
saw. They only show the principle for the design
and function.

Design
The carburettor is based on three sub-systems:

• The metering unit, A.

• The mixing venturi, B.
• The pump unit, C.

The jets and the fuel’s control functions are located In the pump unit (C), fuel is pumped from the fuel
in the metering unit (A). Here the correct quantity tank to the metering unit. One side of the pump di-
of fuel is adjusted for the actual speed and power aphragm is connected to the crankcase and pulses
output. in time with the pressure changes in the crankcase.
The other side of the diaphragm pumps the fuel.
A

12 – English
 Carburettor

Function In the part throttle mode (see figure below) the th-
The carburettor operates differently in the following rottle valve (I) is partially open and the choke valve
modes: (H) is open. Fuel is supplied through the diffuser
jets (D and E).
• Cold start mode
• Idling mode
• Part throttle mode
• Full throttle mode

In the cold start mode (see figure below) the choke

valve (H) is fully closed. This increases the vacuum
D E
in the carburettor so that fuel is sucked more easily
from all the diffuser jets (D, E and F). The throttle
valve (I) is partly open. Extra air inlet (J) is closed.

I H
J

D E F G
In full throttle mode (se figure below) all valves
are open and fuel is supplied through all diffuser
jets (D, E, F and G). Extra air inlet (J) is also fully
H opened.

In the idling mode (see figure below) the throttle D E F G

valve (I and J) is closed and the choke valve (H) is
open.

Air is sucked in through an aperture in the throttle

valve and a small amount of fuel is supplied th-
rough the diffuser jet (D). I H

H
I

English – 13
Carburettor

Carburettor – removal 4
Loosen the screws (x4,D) on the carburettor. Lift
NOTE! the carburettor out of the carburettor compartment.
Do not use knurled pliers to disconnect or
reconnect the fuel hose. This could damage
the hose and lead to leakage or fracture. D D
1
Remove the cylinder cover and air filter. Discon-
nect the leads from the stop switch and the short
circuit spring, and the fuel hoses from the carburet-
tor.
D D
2
Dismantle the throttle actuator rod by pulling out
and lifting up C from its seating. Remove the 5
throttle actuator rod from the lever and then from Remove the cover (A) over the metering unit and
the handle. carefully remove the metering diaphragm (B) and
gasket. See figure below.

6
Remove the screw (E) and take out the needle
valve (D) with lever (C), pin and spring. See figure
below.

C
A

B
3
Loosen the carburettor’s rubber mountings (B).

C
D
E
B

14 – English
 Carburettor

7 Cleaning and inspection

Remove the cover (J) over the pump unit and
carefully remove the gasket (I) and pump diaphragm WARNING!
(G). See figure below number 8. Fuel has the following hazardous
properties:
1. The fluid and its fumes are poi-
8 sonous.
Use a needle or the like to carefully remove the 2. Can cause skin irritation.
fuel filter (F). See figure below. 3. Is highly inflammable.

WARNING!
Never direct the compressed air jet
towards the body. Air can penetrate
into the blood circulation, which
means mortal danger.
F Clean all units in clean petrol.

G Use compressed air to dry the petrol on the com-

ponents. Direct the air through all channels in the
I carburettor housing and make sure that they are
not blocked.

J See figures on previous page and check the fol-

lowing:

1
That gaskets, pump and control diaphragms are
9 undamaged.
Remove caps with the high and low speed screws.
See figure below number 10. 2
That there is no play on the throttle and choke valve
10 shafts.
If necessary, remove the throttle and choke valves
and remove the shafts together with levers and 3
springs. See figure below. The needle valve and lever are not worn at C and D in
figure on previous page.

4
The fuel filter is undamaged.

5
The tips of the high and low speed needles are not
damaged.

6
The intake manifold is undamaged.

7
The carburettor has an extra air shutter connected
in parallel with the ordinary throttle valve. The shut-
ter housing with shaft is secured in the carburettor
using two screws.

English – 15
Carburettor

Assembly 5
Where no figure is referred to, see figure on the Fit the needle valve (D) with lever (C), pin and
previous page. spring and tighten the screw (E). Fit welch plug (K).
See figure below.
Maintain a high level of cleanliness when assem-
bling the carburettor. The slightest contamination C
can result in running problems. D
1
If the throttle and choke valves, together with
levers and springs were removed, they should be
K
E
refitted. Lubricate the shaft bearings with light oil.

2
Fit the high and low speed needles and springs.
Note! Do not fully tighten the screws. This will da-
mage the seats and needle tips.

3
Fit the fuel filter (F) by using the handle of a small 6
screwdriver. See figure below. Check with a ruler or the like that the lever is level
1.65 mm below plane. See figure below. If neces-
4 sary, the lever can be bent slightly.
Fit the pump diaphragm (G), gasket (I) and cover
(J) on the pump unit. See figure below.

F
G

I 7
Fit the control diaphragm (B) with gasket and cover
(A) on the metering unit. See figure below.
J

16 – English
 Carburettor

8 Carburettor – refitting
Fit the air shutter blade on the shaft (L) and con-
nect the throttle actuator rod (N) in parallel with the NOTE!
ordinary throttle valve. The valve housing (P) is Cleanliness is very important when reas-
secured in the carburettor using two screws. sembling the carburettor. Tiny particles of
L dirt can cause operating problems.
A
1
Position the carburettor in the carburettor compart-
N A ment. Fit the carburettor in the rubber mountings
(B).

P
A
A P
9
Carry out a pressure test.
B
Pressure testing
Pressure testing should be carried out with the car-
burettor fully assembled. Testing should always be
carried out after the carburettor has been repaired, B
but it can also be carried out as trouble shooting
before dismantling the carburettor.
2
See figure below and carry out the test as follows: Tighten the carburettor screws (x4,C) with a torque
of 1-1.5 Nm. Fit the fuel hoses (x2,D). Fit the
throttle actuator rod and press down its lock.

D
C C

1 D
Unscrew the high and low speed screws one turn
from closed position. C C
2
Connect pressure tester to the carburettor’s fuel
intake. 3
Connect the leads to the stop switch and the short
3 curcuit spring. Fit the air filter and cylinder cover.
Lower the carburettor into a beaker of water.

4
Pump the pressure up to 50 kPa (0.5 bar).

5
No leakage is permitted. If a leakage occurs refer
to the table below.

Leakage at Fault with

Diffuser jets Needle valve

Leakage in impulse tube Pump diaphragm
Ventilation hole
on metering unit. Control diaphragm

English – 17
Carburettor

Basic adjustment for EPA II saws with capsed • Mount, for this model, approved bar and
carburettors chain combination (see Technical data in the
The chain saw is equipped with a capsed carburet- Operator's Manual).
tor. A slightly different adjustment procedure is nec-
CS 2255 16"
essary when replacing the carburettor or needles.
• The chain should not be tensioned more than
Capsed carburettor that it remains ~ 0,2 inches to the bar.
This means that this chain saw is equipped with
movement limiters on the carburettor’s adjuster
screws. These limit the adjustment range to a
maximum of 1/2 turn.

Replacement of the H-needle or complete car-

burettor
After replacing the carburettor or high speed and/or
1. Carefully screw the new H-needle to the bottom
low speed needle on an EPA (The US Environme-
and turn it anticlockwise ”A” turns.
ntal Protection Agency) certified product, a basic
adjustment must be carried out as described below CS 2255 A = 2 1/2
in order to meet the EPA-requirements. This to 2. Check that:
achieve as low emissions as possible. This instruc- The H-cap is adjusted to its richest setting (tur-
tion is made for EPA certified products only. ned counterclockwise to stop).
The cap is not fixed to the needle, it should
On EPA carburettors both the H- and L-needles are rotate independently.
fitted with caps to prevent the chain saw operator Adjust the L-cap to a center position (1/4 turn coun-
from changing the adjustment above EPA stan- terclockwise = minimum, 1/4 turn clockwise = maxi-
dard. The caps can be removed to achieve richer mum).
or leaner adjustments. To set the needles correctly
an adjustment sleeve is fitted from the factory over 3. Start the engine. If necessary, adjust the idling
the caps to lock them in maximum allowed set- speed with the T-screw until the chain stops.
tings. 4. Adjust the H-needle to give a top speed of ”B”
rpm. Use a tachometer.
When correctly set the caps must be fixed on the
needles. The adjustment sleeve then can be remo- CS 2255 B = 12 500
ved. Over the caps on complete sparepart carbu- Use a narrow blade screwdriver (ref.no. 531 00 48-
rettor, there is a plastic sleeve which is intended to 63) and insert it through the hole in the cap (max.
lock the caps at the richest position (anticlockwise blade width 2 mm/0,08 inch).
towards stop) during the time that the needles
are adjusted. When the adjustment is complete
and the caps have been fixed on the needles, the
sleeve is no longer of any function and can be
removed.

Conditions
• The air filter should be clean and the cylinder
cover fitted when adjustments are made. Adjus-
ting the carburettor with a dirty air filter will give
a too lean fuel mixture the next time the air filter
is cleaned. This can result in serious damage to
the engine.

18 – English
 Carburettor

5. Let the engine run at ”B” rpm ~ 1 minute, until 7. Adjust the L-needle until the highest possible
warm. idling speed is achieved and then turn the L-
needle 1/2 turn counterclockwise. Use a narrow
6. Close the H-needle to a top speed of ”C” rpm.
blade screwdriver (ref.no. 531 00 48-63) and
CS 2255 C = 13 500 insert through the hole in the cap (max. blade
7. Check that the H-cap is still adjusted to its width 2 mm/0,08 inch). Note! If the chain rotates,
richest setting (turned counterclockwise to stop). turn the idling speed screw (T) counterclockwise
Note! The H-needle must not rotate! until the chain stops.

8. Gently knock the H-cap into position. Use a 8. Check that the L-cap is still adjusted to its ri-
5 mm/0,2 inch mandrel (for example the locking chest position (turned counterclockwise to stop).
pin for the bevel gear ref. no. 502 02 61-03). Note! The L-needle must not rotate!
This is a basic carburettor adjustment. Further 9. Gently knock the L-cap into position. Use a
fine adjustments, within the limits the caps allow, 5 mm/0,2 inch mandrel (for example the locking
may be necessary to achieve optimum perfor- pin for the bevel gear ref.no. 502 02 61-03). This
mance. See the Operator's Manual. is a basic carburettor adjustment. Further fine
adjustments, within the limits the caps allow,
may be necessary to achieve optimum perfor-
Replacement of the L-needle mance. See the Operator's Manual.
1. Take off the cap from the L-needle using a pair
of cutting pliers and unscrew the needle.
2. Screw the new L-needle to the bottom and then
turn it counterclockwise ”D” turns.
CS 2255 D = 1 1/2
3. Press a new L-cap on the L-needle to the first
stop, which means that the cap is not fixed to
the needle, it should rotate independently.
4. Adjust the L-cap to the richest position (turned
counterclockwise to stop) without turning the
needle.
5. Let the engine run at ~ ”E” app. 1 minute until
warm and then let it run on idle.
CS 2255 E = 12 500
6. Adjust the idle speed to ”F” rpm.
CS 2255 F = 2700

English – 19
Troubleshooting

Troubleshooting

The various faults that can affect a chainsaw are divided into four groups. In each group the likely
symptoms are given on the left and possible causes are listed on the right. The most likely faults are
given first, and so on.

Starting Idling (low rpm) (cont.)

Difficulty starting Adjust L screw Idles when L Worn needle valve

Air filter blocked screw closed Leaking control diaphragm/cover
Choke not working plate
Worn choke pivot Needle valve assembly sticking
Worn choke valve Worn needle valve lever
Fuel filter blocked Faulty diffuser jet
Fuel line blocked
Piston ring seized Idling uneven Fuel filter blocked
Blocked impulse channel Fuel line blocked
Leaking air intake hose (rubber)
Carburettor Loose or faulty fuel pipe Loose carburettor mounting
leaking fuel Hole in diaphragm bolts
Worn needle valve Worn throttle valve pivot
Needle valve assembly sticking Loose throttle valve screw
Needle valve set too high Worn throttle valve
Leak in metering system (air Needle valve assembly sticking
or fuel) Leak in metering system (air
Loose cover on carburettor or fuel)
pump side Metering system centre knob
is worn
Flooding when Worn needle valve Hole in diaphragm
engine not Needle valve set too high Leaking control diaphragm/cover
running Needle valve assembly sticking plate
Crankcase leaking

Idling (low rpm) L screw requires Fuel line blocked

constant adjust- Needle valve set too high
Will not idle Adjust L screw ment Needle valve assembly sticking
Leaking air intake hose (rubber) Leak in metering system (air
Loose carburettor mounting or fuel)
bolts Leaking control diaphragm/cover
Loose or faulty fuel hose plate
Fuel filter blocked Faulty diffuser jets
Fuel line blocked Crankcase leaking
Fuel tank vent blocked
Throttle valve pivot stiff Too much fuel at Needle valve set too high
Throttle pushrod sticking idling Needle valve assembly sticking
Defective throttle return spring Metering system damaged
Bent throttle stop Worn needle valve
Faulty diffuser jet Leaking control diaphragm/cover
plate
Idling too rich Adjust L screw Metering system incorrectly
Worn needle valve assembled
Needle valve set too high
Worn needle valve lever
Leaking control diaphragm/cover
plate
Needle valve assembly sticking

20 – English
 Troubleshooting

High rpm Acceleration and retardation

Will not run at Adjust H screw Does not Adjust L screw
full throttle Blocked air filter accelerate Adjust H screw
Blocked fuel tank vent Blocked air filter
Blocked fuel filter Blocked fuel tank vent
Fuel line blocked Blocked fuel filter
Loose or damaged fuel hose Fuel line blocked
Impulse channel leaking Loose or damaged fuel hose
Impulse channel blocked Impulse channel blocked
Loose cover on carburettor pump Loose cover on carburettor pump
side side
Faulty pump diaphragm Faulty pump diaphragm
Leaking air intake hose (rubber) Leaking air intake hose (rubber)
Loose carburettor mounting bolts Loose carburettor mounting bolts
Needle valve set too low Needle valve set too low
Metering system damaged Metering system incorrectly
Metering system incorrectly assembled
assembled Needle valve assembly sticking
Leaking control diaphragm/cover Faulty diffuser jets
plate Blocked silencer
Needle valve assembly sticking
Blocked silencer Engine stalls Adjust L screw
when throttle Adjust H screw
Low power Adjust H screw released Faulty pump diaphragm
Blocked fuel tank vent Needle valve set too high
Blocked fuel filter Needle valve assembly sticking
Impulse channel leaking Faulty diffuser jets
Impulse channel blocked Adjust L screw
Over rich
Loose cover on carburettor pump Adjust H screw
acceleration
side Blocked air filter
Faulty pump diaphragm Faulty pump diaphragm
Blocked air filter Faulty diffuser jets
Needle valve assembly sticking
Leak in metering system (air or
fuel)
Metering system incorrectly
assembled
Loose diaphragm rivet
Hole in diaphragm
Leaking control diaphragm/cover
plate
Troubleshooting methods
In addition to the faults described in the above ta-
ble, trouble shooting can be carried out on specific
components or sub-systems of the chainsaw. The
various procedures are described in the relevant
chapters, see the contents page, as follows:

• Checking the operation of the chain brake

• Measuring the resistance of the stop plate
• Pressure testing the carburettor
• Pressure testing the decompression valve
• Pressure testing the cylinder

English – 21
Repair instructions

Repair instructions
Chain brake – dismantling 3

1 WARNING!
Disengage the brake by pushing the kickback Make sure the spring does not
guard backwards. Unscrew the bar nut and fly out and cause injury. Wear eye
remove the clutch cover, chain and bar protection.

Remove the screws and carefully remove the cover

from the chain brake spring.

2
Grip the clutch cover carefully in a vice. Release
the brake spring by using the kickback guard from
the saw as a tool. Engage it with the brake mecha-
4
nism and turn anticlockwise to activate the brake.
Place one hand over the spring and insert a small
screwdriver between the bottom end of the spring
and the clutch cover. Carefully prise the spring up-
wards so that it slides onto the screwdriver shaft.

Cleaning and inspection

• Clean and inspect all parts carefully. If there are
any cracks or other defects replace the damaged
parts with new ones. Always use original parts.
• Measure the thickness of the chain brake band.
It must be no less than 0.6 mm at any point.
• Lubricate the elbow joint with grease.

min 0,6 mm

22 – English
 Repair instructions

Chain brake – reassembly 4

Tension the brake spring by using the kickback
1
guard from the saw as a tool. Engage it with the
Bolt the elbow joint to the brake band and tighten
brake mechanism and turn clockwise to release the
to a torque of 1–1.5 Nm.
brake.
Locate the elbow joint and connected brake band
in their recesses in the clutch cover. Lubricate the
recess for the spring with grease.

5
Turn the chain tensioner anticlockwise as far as it
2 will go.
Grip the clutch cover in a vice. Compress the
spring with special tool 502 50 67-01 and push it Refit:
down with your thumb. • guide bar

WARNING! • chain
Make sure the spring does not • clutch cover
fly out and cause injury. Wear eye
protection. NOTE!
After completing the repair the chain
brake must be tested as described below.

Operating test:
The engine must not be running during the test.

Guide bar length Height

38cm/15" 50 cm/20"

• Hold the chainsaw over a firm surface. The

height of the guide bar above the surface is
given in the table above.
• Let go of the front handle and let the chainsaw
3
fall towards the surface.
Fit the cover over the chain brake spring, tighte-
ning the screws to a torque of 1–1.5 Nm. • When the guide bar hits the surface the chain
brake must engage.

English – 23
Repair instructions

Silencer – removal Silencer – refitting

WARNING! 1
Do not touch the silencer until it If the saw is equipped with a spark arrestor mesh
has cooled down, otherwise you this should be fitted first.
may burn yourself.
2
1 Refit
Remove the cylinder cover, silencer, gasket and • cooling plate
cooling plate. • gasket
• silencer, tighten bolts to a torque of 8–10 Nm.
• cylinder cover

3
Run the saw for at least 1 minute, then retighten
the silencer bolts to 8–10 Nm.
A
Chain catcher – replacement
If the chain catcher is worn it must be replaced with
a new one.
2
If the saw is fitted with a spark arrestor mesh this 1
must also be removed. Release the brake by pushing the kickback guard
backwards. Undo the guide bar bolts and remove
the clutch cover, chain and guide bar.
Cleaning and inspection
Clean and inspect all parts carefully. If there are
2
any cracks or other defects replace the damaged
Remove the chain catcher and replace it with a
parts with new ones.
new one. Check that the vibration damping spring
The spark arrestor mesh is best cleaned with a
locates correctly against the crankcase when you
wire brush. If the mesh is damaged it must be
bolt the new chain catcher in position.
replaced.
If the mesh is blocked the saw will overheat and
this will cause damage to cylinder and piston.
Never use the saw with a silencer that is in poor
condition. Always use original parts.

3
Turn the chain tensioner anticlockwise as far as it
will go.

Refit:
• guide bar
• chain
• clutch cover

24 – English
 Repair instructions

Stop switch – removal Cleaning and inspection

Clean and inspect all parts carefully. If there are
1 any cracks or other defects replace the damaged
Remove the cylinder cover and air filter. parts with new ones. Always use original parts.
2
Disconnect both leads from the stop switch and the
Stop switch – resistance measurement
short circuit spring. Remove the short circuit spring Clean the mating surfaces and check the resis-
by carefully sliding it out. tance as follows:

3
Carefully prise the carburettor assembly off the left-
hand rubber mounting using a small screwdriver.

Measure the resistance by connecting a multimeter

to the ignition coil. NOTE! The switch must be in
the “on” position to give the correct reading.

The resistance must not be higher than 0.5 Ω

when the switch is in the on position.

4
Carefully loosen the stop switch’s tab from the air
filter holder at the same time as moving the switch
straight out.

English – 25
Repair instructions

Stop switch – refitting Choke control – removal

1 1
Carefully press the new stop switch into place. Remove the cylinder cover, air filter and stop
Check that the switch’s upper mounting clips over switch.
the air filter holder.
2
Tilt the carburettor.

3
Compress the clip that holds the choke control to
the carburettor while pulling it out at the same time.
Disconnect the choke control from the air filter
holder.

2
Refit the short circuit spring. Engage the short
circuit spring in the front slot first then lift the rear
edge onto the stop switch. Slide the short circuit
spring in as far as it will go.

3
Refit:
• the leads to the short circuit spring and stop
switch
• left rubber mounting
• air filter
• cylinder

26 – English
 Repair instructions

Choke control – refitting Throttle lock, throttle trigger and return

First reattach the choke control to the air filter holder, spring – refitting
then press it onto the carburettor so that the clips 1
engage. Refit the return spring to the throttle trigger as
shown. Make sure the spring is correctly positioned
Then refit: by engaging the short hook in the triangular resess
• stop switch in the throttle trigger (A).
• check that the rubber guide over the carburettor
screws is seated correctly
• carburettor into its rubber mountings
• air filter and cylinder cover

Throttle lock, throttle trigger and return

spring – removal
1
Loosen the handle screws (3) and remove the
cover.

2
Fit the throttle in the handle.

2
Remove the throttle lock from the handle. Remove
the spring and throttle trigger.

3
Place the return spring into the rear compart-
ment of the throttle lock. Fit the throttle lock in the
handle. NOTE! The long hook of the spring shall
pass the throttle lock on the left side. Fit the cover.

4
Check the operation of the throttle lock by trying to
Cleaning and inspection press the throttle trigger without pressing down the
• Clean and inspect all parts carefully. If there are throttle lock. Also check that the throttle lock and
any cracks or other defects replace the damaged throttle trigger return freely to their original posi-
parts with new ones. Always use original parts. tions when released.
• Check that the spring is not broken and has not
lost its tension.

English – 27
Repair instructions

Starter assembly – removal Replacing a broken or worn starter cord

1 1
Undo the four bolts that fasten the starter assembly Before replacing a worn starter cord the tension in the
to the crankcase and lift off the starter assembly. recoil spring must be released. Pull the starter cord out
through the notch in the pulley rim and wind the pulley
anti-clockwise to release the tension in the spring.

2
Pull out about 30 cm of the cord and fasten it in the
notch in the pulley rim. Release the tension in the
return spring by letting the pulley wind backwards
slowly. 2
Remove the bolt from the centre of the pulley and
3 lift off the pulley.
WARNING!
3
If the recoil spring is still under
Fit a new cord through the hole in the pulley and tie
tension when the pulley is re-
a knot to secure it. Feed the other end of the cord
moved it can fly out and cause
through the hole in the starter housing and through
injury. Wear eye protection.
the starter handle, then tie a double knot in the
end. Wind about 3 turns of the starter cord onto the
pulley. Fit the bolt through the centre of the pulley
and tighten to a torque of 2–3 Nm.
Remove the bolt from the centre of the pulley and
lift off the pulley.

Cleaning and inspection

Clean the parts and check the following:
• The starter cord.
• That the pawls on the flywheel are undamaged,
i.e. that they spring back towards the centre and
move freely.
• Lubricate the return spring with light oil.

28 – English
 Repair instructions

Cleaning and inspection Replacing a worn recoil spring

• Clean and inspect all parts carefully. If there are
any cracks or other defects replace the dama- WARNING!
ged parts with new ones. Lubricate the return Make sure the recoil spring does
spring with a little grease. not fly out and cause injury. Wear
eye protection.

1
Remove the bolt from the centre of the pulley and
lift off the pulley and spring cassette.

2
Replace the defective spring cassette with a new
one.

3
Fit the bolt through the centre of the pulley and
tighten to a torque of 2–3 Nm.
Tension the recoil spring, see “Tensioning the recoil
spring”.

Starter assembly – refitting

1
Position the starter assembly on the crankcase and
tighten the bolts to a torque of 2.5–3.5 Nm.

Tensioning the recoil spring

1
Fasten the starter cord in the notch in the pulley
rim and wind the pulley about 3 turns clockwise.
Check that the pulley is free to rotate at least an-
other half turn when the starter cord is fully exten-
ded.

English – 29
Repair instructions

Ignition module – testing 2

If replacing the ignition module, disconnect its leads
If there is a fault in the ignition system the ignition and unscrew it. The ignition module can be left in
module must be tested before the ignition system place if you are simply removing the flywheel.
is removed.

Test the ignition module as follows:

• Connect a test spark plug 502 71 13-01 to the

ignition lead and clip the test spark plug onto the
3
cylinder.
Loosen the flywheel nut using a suitable socket and
• Turn the engine over using the starter cord. remove it. Fit the punch as shown below, leaving a
space of appr. 1mm to the flywheel.
• If the test spark plug produces a spark the igni-
tion module is OK.

Ignition module/flywheel – removal

1
Remove the cylinder cover. Disconnect the HT lead, 1mm
remove the spark plug and fit piston stop 502 54 15-01
in its place. Take off the starter assembly, release the
leads from the cable guide and remove it.

4
Knock on the punch using a metal mallet until
the flywheel releases from the shaft. Remove the
punch and the flywheel.

Cleaning and inspection

• Clean all parts, especially the tapers on the
flywheel and shaft.
• Check that the flywheel is not cracked or dama-
ged in any other way.

30 – English
 Repair instructions

Ignition module and flywheel – refitting 3

Then refit:
1 • cable guide and press the leads into position
Place the flywheel on the crankshaft. Turn the
• HT lead
flywheel so that the key lines up with the keyway in
the shaft. • starter assembly, tighten to a torque of 2.5–3.5 Nm
• cylinder cover
Fit the nut on the shaft and tighten to a torque of
25-30 Nm.

2
To refit the ignition module proceed as follows:

Turn the flywheel so that the magnets are in line

with the ignition module. Fit the ignition module with
the plastic feeler gauge (502 51 34-01) held in po-
sition at the same time, without tightening the bolts.
Connect the black earth lead to the front screw on
the ignition module. Adjust the gap between the igni-
tion module and magnet to 0.3 +/- 0.1 mm. The gap
must be measured at either of the two lowest pegs
on the ignition module. Tighten the bolts to 4.5–6
Nm. Connect the blue lead to the ignition module.

0,3 mm

English – 31
Repair instructions

Centrifugal clutch – removal Inspection and cleaning

• Clean and inspect all parts carefully. If there are
1 any cracks or other defects replace the dama-
Remove the cylinder cover. Disengage the chain ged parts with new ones. Always use original
brake by pushing the kickback guard backwards. parts.
Undo the guide bar bolts and remove the clutch
cover, chain and guide bar.

2
Disconnect the HT lead. Remove the spark plug
and fit piston stop 502 54 15-01 in its place.

Min 65mm
• Check the thickness of the clutch shoes by
using vernier callipers to measure the diameter
of the clutch. If the diameter is less than 65 mm
the clutch assembly must be replaced.

Centrifugal clutch – refitting

1
3 Insert the clutch springs in the shoes using circlip
pliers.
Unbolt the clutch using tool 502 54 16-01 and a
suitable socket or wrench. Turn the clutch clock- NOTE!
wise to remove it.
Handle the clutch springs carefully. If they
are opened up too much they could dam-
A age the saw.

4
Carefully prise out the clutch springs with a screw-
driver.

NOTE!
Handle the clutch springs carefully. If they
are opened up too much they could dam-
age the saw. 2
Fit the clutch onto the crankshaft and tighten
anticlockwise as far as it will go. Then tighten to a
torque of at least 20 Nm using tool 502 54 16-01
and a suitable socket or wrench.

32 – English
 Repair instructions

3 3
Remove the piston stop. Fit the spark plug, tightening Unbolt the oil pump from the crankcase and
it to a torque of 15 Nm, then connect the HT lead. remove it together with the oil pressure hose.
Then refit:
• cylinder cover
• guide bar
• chain
• clutch cover

Dismantling the oil pump and screen

1
Empty and clean the oil tank.

Remove the cylinder cover. Disengage the chain

brake by pushing the kickback guard backwards. 4
Undo the guide bar bolts and remove the clutch co- The oil pump is adjustable. Remove the pin (B)
ver, chain and guide bar. Disconnect the HT lead. from the adjuster screw, using a small drift to press
Remove the spark plug and fit piston stop 502 54 it out.
15-01 in its place. Unscrew the clutch (clockwise)
using clutch tool 502 54 16-01 and a suitable Press in the pump piston (C) so that the adjuster
socket spanner or combination spanner. screw (D) can be removed. Remove the pump
piston.
2
Remove the centrifugal clutch. Remove the clutch
drum (A), needle bearing (C) and pump drive
wheel (D).
D
C
A

Cleaning and inspection

• Clean and inspect all parts carefully. If there are
any cracks or other defects replace the damaged
parts with new ones. Always use original parts.
• Lubricate all moving parts with chain oil.

English – 33
Repair instructions

Assembling the oil pump and screen 5

Fit the chain guide plate, tightening the bolt to a
1 torque of 2–3 Nm.
Lubricate the pump piston (C) with oil and fit the
pump piston and washers. Fit the pump gear, needle bearing, clutch drum and
C clutch (min. 20Nm).

Fit the chain, bar and clutch cover.

B
D
2

2
Press the pump piston (C) in position in house (A).
Fit the adjuster screw and spring so that the pin (B)
can be pressed into position.
Adjusting the oil pump
3 Use a screwdriver to turn the adjuster screw on the
Fit the oil suction hose (2) with screen in the oil pump. Turning the screw clockwise decreases the
tank. oil flow and turning it anti-clockwise increases the
oil flow.
WARNING!
Poor chain lubrication can result
in failure of the chain, which could
cause serious or fatal injury.

4
Bolt the oil pump to the crankcase. It must be bol-
ted to a torque of 2–3 Nm. Replace the oil pressure
hose.

Recommended setting:
13–15" bar Min. setting
15–18" bar Midway setting
18–20" bar Max. setting

34 – English
 Repair instructions

Air intake system – removal Air intake system – refitting

The air intake system comprises: 1
• intake manifold (A) Fit the carburettor flange and the air flange on the
intake manifold and the impulse hose, intake mani-
• insulating plate (B)
fold and insulating plate on the cylinder.
• air flange (C)
• carburettor flange (D)
• impulse hose (E)

2
Place the new cylinder base gaskets on the crank-
case. Fit the cylinder on the crankcase by pressing
the cylinder gently down onto the crankcase and
C then carefully turn the saw so that the cylinder
B base gasket does not slide out of position.
A
D

1
Remove:
• cylinder cover
• air filter
• carburettor
• vibration element on the cylinder (F)
• cylinder screws (x4)

3
Tighten the cylinder base screws (x4) with a torque
of 13 Nm. Fit the vibration element on the cylinder.
Now assemble the spark plug cap, carburettor, air
filter, handle system and the cylinder cover.

• handle system (3 screws)

• hand guard

2
Carefully remove the cylinder (see Piston and
cylinder removal). Knock on the crankshaft and/or
flywheel using a plastic mallet. Loosen the impulse
hose and the screws (x3) holding the intake mani-
fold on the cylinder. Remove the insulating plate. Cleaning and inspection
Clean and inspect all parts carefully. If there are
any cracks or other defects replace the damaged
parts with new ones. Always use original parts.

NOTE! When replacing the impulse hose it

must not be lubricated with oil or grease.

English – 35
Repair instructions

Replacing the fuel filter Fuel tank vent

The two-way valve has the following properties:
NOTE!
• Has a controlled opening pressure outwards and
Do not use knurled pliers to disconnect or inwards that prevents overpressure and under-
reconnect the fuel hose. This could dam- pressure arising in the fuel tank, which can af-
age the hose and lead to leakage or frac- fect the engine. This also impedes fuel leakage.
ture.
• Opening pressure outwards 100-450 mbar.
1 • Opening pressure inwards (vacuum) max.
First remove the old fuel filter from the tank unit 70 mbar.
using special tool 502 50 83-01.
Testing
2 Opening pressure outwards:
Pull the fuel hose out of the tank and pull off the 1. Open the fuel cap and let the fuel cap remain
filter. off during the entire check. Empty the fuel from
the tank.
3 2. Connect the pump, part no. 531 03 06-23 to
Fit the new fuel filter and feed the fuel hose back the tank valve.
into position. 3. Switch the pump to vacuum mode.
4. Pump 3 times.
5. The indicator should stop in between
Replacing the fuel hose 10-45 kPa after pumping.

NOTE! Opening pressure inwards:

Do not use knurled pliers to disconnect or 1. Open the fuel cap and let the fuel cap remain
reconnect the fuel hose. This could dam- off during the entire check. Empty the fuel from
age the hose. the tank.
2. Connect the pump, part no. 531 03 06-23 to
1 the tank valve.
Loosen the hose from the carburettor and pull the 3. Switch the pump to pressure mode.
hose up through the fuel cap opening. 4. Pump 3 times.
5. The indicator should stop on max 7 kPa
2
after pumping.
Insert tool 502 50 83-01 in the hose bushing in the
bottom of the carburettor compartment and out
through the tank opening. Secure the new hose on
the end of the tool and, by using the tool, pull the
hose through the hose bushing. Cut off the angled
parts of the hose at both ends and then fit the hose
on the carburettor and fuel filter.

36 – English
 Repair instructions

Tank vent replacement 5

Remove the circlips from the ends of the gudgeon
Pull out the tank vent with a pair of knurled flat pin and press it out. Then lift off the piston.
pliers.

6
Gently push the new tank vent into place using a Remove the bearing from the little end of the con-
suitable sleeve. necting rod.

Piston and cylinder – removal

1
Remove:
• cylinder cover
• carburettor (see “Carburettor – removal”)
• silencer
• spark plug
• hand guard (2 screws)
2 If replacing the cylinder:
Unbolt the vibration damping spring from the front Remove the intake manifold, see “Air intake sys-
handle. tem – removal”.

Cleaning and inspection

Clean all the components, scraping off all traces of
old gasket and carbon from the following places:
• Piston crown
• Top of the cylinder bore
• Cylinder exhaust port
• Decompression valve channel
• Cylinder base and/or crankcase

Check the following:

3 • The surface coating of the cylinder is not worn
Undo the four cylinder bolts from the underside through, especially in the upper part of the cylin-
and lift the cylinder off carefully. der.
• The cylinder is free from score marks and areas
4
of wear.
Cover the opening in the crankcase.
• The piston is free from score marks. Small scrat-
ches can be polished out with fine emery paper.
• The piston ring is freely moving in its groove.

English – 37
Repair instructions

Piston and cylinder – refitting

1
Lubricate the little end bearing with two-stroke oil
and insert it in the connecting rod.

• Measure piston ring wear. This should not

exceed 1 mm. Use the piston to push the piston 2
ring for correct alignment. Fit the piston with the arrow pointing towards the
• The needle roller bearing is undamaged. exhaust port. Push the gudgeon pin in and fit the
circlips. If replacing the cylinder, fit the decompres-
• The intake manifold is undamaged. sion valve, tightening to a torque of 12–14 Nm.
• That the air hoses and impulse hose are unda-
maged.
• Pressure test the decompression valve.

Decompression valve – pressure

testing
1

3
Fit the intake manifold on the cylinder, with insula-
ting plate (3 screws).

Connect tool 531 03 06-23 to the decompression

valve.

2
Pump the pressure up to 80 kPa (0.8 bar). NOTE!
It is very important that there are no leaks
3 in the inlet system, otherwise the engine
Wait 30 seconds. may seize.

4
The pressure should not be less than 60 kPa
(0.6 bar).

38 – English
 Repair instructions

4 Cylinder – pressure testing

Lubricate the piston ring and piston with two-stroke
oil.

5
Fit new cylinder base gaskets. Lower the cylinder
over the piston carefully.

1
Remove:
• cylinder cover
6 • carburettor
Fit the cylinder bolts, tightening them in diagonal
pairs to a torque of 13–15 Nm. • spark plug

2
Loosen the screws on the muffler and press the
rubber sheet 502 54 11-02 between the muffler
and cylinder. Tighten the top two muffler screws.

3
Attach both the pressure testing covers. See the
figure.

4
Fit the pressure testing spark plug 503 84 40-02
and connect the pressure testing tool 531 03 06-23.

7 5
Pressure test the cylinder. Pump the pressure up to 80 kPa (0.8 bar). Wait
30 seconds. The pressure should not be less than
8 60 kPa (0.6 bar). Remove the cover plates from
Refit: the silencer and carburettor, tighten the bolts to the
• spark plug, tighten to a torque of 15 Nm specified torque. Remove the pressure test nipple
• carburettor, see “Carburettor – refitting”, 503 84 40-02 and refit the spark plug.
• silencer, tighten to a torque of 12–14 Nm
WARNING!
• cylinder cover After pressure testing the cylinder,
check that the inlet manifold is
seated correctly, otherwise the saw
NOTE! may be damaged.
If a new piston or cylinder has been fitted
the saw must be run for the first 3–4 hours
with carburettor adjusted to the factory
settings.

English – 39
Repair instructions

Crankshaft complete - dismantling Crankshaft bearings – replacement

1
Remove:
Remove the following:
• The crankshaft complete from the crankcase.
• chain and bar
• clutch cover
• cylinder cover
• starter assembly*
• centrifugal clutch*
• throttle pushrod
• carburettor*
• silencer*
• handle system
• hand guard
• piston and cylinder*
* See special instructions. 1
Pull the crankshaft bearing off of the crankshaft
using a bearing puller.
2
2
Place a new bearing on the shaft and push into
position using tool 502 50 30-18. See figure.

Lift the crankshaft completely out of the crankcase.

40 – English
 Repair instructions

Crankshaft complete – reassembly Repairing damaged threads

A repair kit, 503 27 33-01, is available for repairing
damaged threads.

First drill out the hole using:

6.1 mm drill bit for magnesium crankcase

6.0 mm drill bit for plastic crankcase

Then screw in the thread insert using a suitable

bolt and spanner.

1
Fit the crankshaft complete in the crankcase.

Refit the following parts:

• piston and cylinder*
• handle system
• hand guard
• silencer*
This type of thread insert is best suited for use
• carburettor* in plastic and magnesium, but not for repairing
• throttle pushrod threads in aluminium. In that case use a helicoil
insert with metric screw.
• centrifugal clutch*
• starter assembly*
Changing the front bar bolt
• cylinder cover
1
• clutch cover
Drain the oil tank.
• chain and bar
2
* See special instructions.
Knock through the old guide bar bolt so that it falls
into the oil tank. (The plastic skin covering the head
will break.)

3
Remove the bolt from the oil tank.

4
Fasten a steel wire to the thread of the new bolt,
feed the steel wire into the oil tank and out through
the bolt hole in the crankcase.

English – 41
Repair instructions

5
Pull the steel wire until the bolt comes out through
its hole.

6
Pull through the bolt with its nut. Place a spacer
between the nut and crankcase.

7
Check that the square shoulder of the bolt is cor-
rectly seated in the recess in the crankcase.

8
Refill with chain oil.

Changing the rear bar bolt

1
Dismantle the cylinder cover, hand guard and
muffler.

2
Knock in the bar bolt.

3
Pull a new bar bolt in place with help of a nut and
spacer like for the front bar bolt.

4
Check that the square shoulder of the bolt is cor-
rectly seated in the recess in the crankcase.

42 – English
505 48 19-26 2008W21

English – 44