Husqvarna 235E Chailsaw OEM Service & Repair Manual

101 90 74-26 Workshop Manual Brush Cutters, Trimmers, Pruners, Pruning Saws, Hedge Trimmers, Ice Drills, Blowers For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

1 © Copyright Husqvarna AB, Sweden Workshop Manual Brush cutters, Trimmers, Pruners, Pruning saws, Hedge trimmers, Ice drills, Blowers General recommendations ______________________ 2 1. Starter __________________________________ 3 2. Ignition system ___________________________ 25 3. Fuel system _____________________________ 39 4. Centrifugal clutch _________________________ 81 5. Angle gear _____________________________ 107 6. Cylinder and piston ______________________ 119 7. Crankshaft and crankcase _________________ 147 8. Hydraulic unit ___________________________ 181 9. Cutting equipment _______________________ 191 10. Tools __________________________________ 209 The Manual covers the models: 265, 250, 252, 240/245 225 / 232 / 235 / 240 RBD 322/325 122, 32, Mondo 250PS, 235 P 225 H 60 / 225 H 75 225AI15, 225AI25 18H, 140B, 141B 132HBV, 225BV, 225HBV Contents For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

2 502 51 03-01 General recommendations Bear in mind: ● Do not start the engine without the clutch drum and driveline fitted as the clutch can become detached and cause severe personal injury. ● Do not touch hot components, e.g. the muffler and clutch before they have cooled sufficiently to avoid burns. ● Avoid getting fuel or oil on your skin or in your mouth. Use a barrier cream on your hands. This reduces the risk of infection and makes dirt easier to wash away. Long term contact with engine oil can represent a health hazard. ● Never start the engine indoors. Exhaust fumes are poison- ous! ● Wipe up oil spills from the floor immediately to avoid slipping. ● Do not use tools that are worn or fit badly, for example on nuts and bolts. ● Always work on a clean bench. ● Always work logically to ensure all parts are fitted correctly and that nuts and bolts are tightened. ● Use the special tools where recommended to be able to carry out the work correctly and efficiently. Special tools Some of the work described in the Workshop Manual requires special tools. In each section where this is necessary there is a picture of the tool and an order number. We recommend the use of special tools in order to avoid expensive damage to parts in question and personal injury and to provide an efficient repair procedure. Contact faces and gaskets Ensure all surfaces are clean and free from gasket residue, etc. When cleaning use a tool that will not damage the contact face. Any scratches or unevenness should be removed using a flat fine cut file. Sealing rings Always replace a sealing ring that has been dismantled. The sensitive sealing lip can easily be damaged resulting in inferior sealing capacity. Surfaces which the seal shall seal against must also be completely undamaged. Lubricate the sealing lip with grease before it is fitted and ensure that it is not damaged e.g. by shoulders and splines on a shaft. Use tape or a conical sleeve as protection. It is important that the sealing ring faces in the right direction for it to act as it is intended. The workshop used to carry out repairs must be equipped with safety devices in accordance with local directives. No one may carry out repairs without first having read and understood the contents of this Workshop Manual. The boxes below can be found in appropriate parts of this manual. WARNING! The warning box warns of the risk for per- sonal injury if the instructions are not fol- lowed. ! NOTE! This box warns of damage to material if the instruc- tions are not followed. The machine is type approved for safety in accordance with applicable legislative demands with the equipment specified in the Operator’s Manual. The assembly of other equipment or accessories or spare parts not approved by Husqvarna can result in the failure to meet these safety demands and that the person carrying out assembly bears responsibility for this. Poisonous fumes When using cleaning agents read the instructions carefully. Ensure there is good ventilation when handling petrol and other volatile fluids. The engine's exhaust fumes are poisonous. Test run the engine outdoors. Fire risk Handle fuel with respect as it is extremely inflammable. Do not smoke and ensure there are no open flames or sparks in the vicinity. Make sure there is a working fire extinguisher close at hand. Do not try to extinguish a petrol fire with water. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

3 1. Starter Contents Dismantling General ______________________________________ 4 Model 265 Dismantling, assembly __________________________ 4 Model 250/252 Dismantling, assembly __________________________ 7 Model 240/245 Dismantling, assembly __________________________ 9 Model 225, 232, 235, 240 Dismantling, assembly _________________________ 11 Model 322, 325 Dismantling, assembly, replacement of the drive dogs ___ 13 Model 122 Dismantling, assembly _________________________ 15 Model 32, Mondo, Mondo Mega Dismantling, assembly _________________________ 17 Model 18H Dismantling, assembly _________________________ 21 Model 140B, 141B Dismantling, assembly _________________________ 22 Assembly, general ____________________________ 24 Replacing the drive dogs _____________________ 24 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

4 1 Starter WARNING! Protective glasses must be worn when working on the starter to prevent injury to the eyes, if for some reason, the return spring should fly out. ! Dismantling General Dismantle the starter from the engine body. Dismantling General Remove all bolts and lift off the starter. On some models the cylinder cover and tank filler cap must be removed. Model 265 Dismantling Release the spring pressure. Model 265 Dismantling Release the spring pressure. Pull out the starter cord approx. 30 cm. Hold the starter pulley with your thumb and place the cord in the cut-out on the starter pulley rim. Let the starter pulley slowly recoil. NOTE! Stop the spring with your thumb. ! WARNING! Exercise care so that the screw tip on the cord at- tachment does not injure your thumb. Remove the screw and washer in the centre of the starter pulley and bearing sleeve. Lift out the starter pulley. Remove the screw and washer in the centre of the starter pulley and bearing sleeve. Lift out the starter pulley carefully so that the spring does not follow and fly out. WARNING! Wear protective glasses. The return spring can fly out and cause personal injury. ! For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

5 1 A B Starter Remove the spring from the starter hous- ing. Assembly Insert a new spring in the starter housing. Remove the spring from the starter hous- ing by knocking it against a bench with the spring facing downwards. WARNING! Wear protective glasses. ! Assembly Fit a new return spring if necessary. Let the spring retainer ring remain in place. 1. Place the spring over its seating in the starter housing 2. Push the spring into its right position using your thumb and let the retainer ring slide off the spring. 3. Lubricate the spring with a few drops of oil. NOTE! Do not forget the Pertinax disc be- tween the spring and the starter housing. ! WARNING! Wear protective glasses. Check the starter pulley's bearing. If necessary replace the sleeves (A) and (B). Check the starter pulley's bearing. If it is heavily worn the bearing sleeve (A) can be replaced. Cut out the sleeve and press in a new sleeve. If there is still too much play on the bear- ing a new metal sleeve (B) should also be fitted. If necessary replace the starter cord. If necessary replace the starter cord. Thread the new cord through the hole in the starter pulley as shown in the illustra- tion and screw the plastic cube on the end of the cord. Let it protrude approx. 3 mm and melt it using a soldering iron to en- sure a secure fastening is obtained. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

6 B 1 Starter Wind the cord around the starter pulley about 3 turns clockwise and position the pulley in the starter housing. Tip! The knot on the starter cord in the handle can be difficult to undo. It is easier if you place the knot on a hard surface and hit it with a hammer. Wind the cord around the starter pulley about 3 turns clockwise and position the pulley in the starter housing. Check that the return spring grips the starter pulley hub correctly. Fit the washer and screw that hold the starter pulley. Lubricate the bearing sleeve (B) with a few drops of oil and insert the starter pulley. Fit the washer and screw. Use Loctite on the screw. Fit the starter handle on the cord. Insert the cord through the cord guide in the starter housing and anchor it in the starter handle by tying a knot. Fold down the free ends and pull the knot fully into the starter handle. Tension the return spring. To tension the return spring pull out the starter cord fully and lift it into the cut-out in the starter pulley. Hold the pulley using your thumb then tension the spring by turning the starter pulley clockwise approx. 2 turns. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

7 1 + 1/2 r Max Starter Check the spring tension. Check the spring tension. It should be possible to turn the starter pulley at least a further half turn with the starter cord fully extended. Model 250 Dismantling Release the spring tension. Remove the starter pulley. Model 250 Dismantling Release the spring tension in the same way as described for model 265. Remove the screw in the centre of the starter pulley and lift out the pulley. Carefully remove the spring cassette so that the spring does not fly out. Remove the screws and lift out the spring cassette. Check the starter pulley and starter hous- ing for wear and damage. Despite the spring sitting in a cassette it can still fly out when the cassette is pried from the guide pin when inserting the cord in the starter housing. Check the following: 1. Wear on the drive pins on the starter pulley. If necessary replace the starter cord. 2. Nut in the nut pocket is in position and the thread is undamaged. 3. Cord entry in the starter housing. If worn the housing should be replaced. ! WARNING! Wear protective glasses. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

8 1 Starter Assembly Fit a new spring cassette if necessary. Assembly Lubricate the return spring with a few drops of oil or a cold resistant grease. Ensure the spring has been pressed down to the bottom of the cassette especially at the fastening points. Fit the spring cassette in the starter hous- ing. Press the spring cassette into the starter housing and tighten the screws. Check that the end of the spring is approx. 3 mm from the spindle to help assembly of the starter pulley. Lubricate the surface of the cassette with oil or cold resistant grease. Fit a new starter cord. Fit a new starter cord. Tie a small knot on the cord and melt the ends of the cord so that is does not fray. Wind the cord approx. 3 turns anticlock- wise on the starter pulley. Tip! First thread the cord straight through the hole in the starter pulley and then back again and out through the slot. Fit the starter pulley. Lubricate the spindle in the starter hous- ing with a few drops of oil and position the starter pulley and tighten the screw. Fit the starter handle as described for model 265, but tie a double knot as the cord is lighter. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

9 1 Max + 1/2 r Starter Tension the return spring. To tension the return spring. Wind the cord 2 turns anticlockwise around the hub on the starter pulley and pull out the starter handle until the cord is extended. Repeat the procedure once more. Check the spring tension. NOTE! With the starter cord fully extended it must still be possible to turn the starter pulley at least a further half turn. Models 240/245 Dismantling Release the spring. Remove the starter pulley. Models 240/245 Dismantling Release the spring tension as described for model 265. Remove the screw and washer and lift out the starter pulley. ! WARNING! Wear protective glasses. Lift out the spring cassette. The spring cassette sits freely in the starter housing and can easily be lifted out to be replaced. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com