HUSQVARNA CHAIN SAWS 36 41 40 45 51 55 42 242XP 246 254XP 257 262XP 61 268 272XP 272S 268K 272K 3120XP 394XP 281XP 288XP Workshop Service Manual

101 88 55-26 Workshop Manual Husqvarna Chain Saws For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

2 – English LIST OF CONTENTS Introduction ..................................... 3 Safety regulations ........................... 5 Technical Data ................................. 6 Tools ............................................... 14 Service data ................................... 20 Trouble shooting ........................... 40 Safety equipment .......................... 42 Starter ............................................. 57 Electrical system ........................... 61 Centrifugal clutch .......................... 67 Lubrication system ....................... 70 Carburettor ..................................... 83 Air filter ........................................ 101 Tank unit ....................................... 103 Anti-vibration system .................. 106 Piston cylinder ............................. 108 Crankcase and crankshaft .......... 114 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 3 INTRODUCTION As production continues, changes will be intro- duced 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 prob- lems, the manual should always be read together with all service announcements that apply to the specific model of chain saw. Layout 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. General Updates Always use Husqvarna original: • Spare parts • Service tools • Accessories 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. Tools This workshop manual provides a detailed description of procedures for trouble shooting, repair and testing of the chain saws. Safety precautions that should be taken during repair are also described. This workshop manual applies to the engine assembly in the following chain saws: 36 40 41 42 45 51 55 61 242XP 246 254XP 257 262XP 268 272XP 268K 272K 272S 281XP 288XP 394XP 3120XP 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. Target group 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. 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. For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

4 – English INTRODUCTION Dismantling and reassembly of the entire chain saw When the entire chain saw is to be dismantled and reassembled, proceed as follows: 1. Refer to page 57, which deals with the Starter and carry out the instructions under the heading Dismantling. 2. Work forwards through the manual and carry out Dismantling instructions in the order that the sections occur. 3. 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. Use This workshop manual can be used in two different ways: • Repair of a specific sub-assembly • Dismantling and reassembly of the entire chain saw 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 sub- assembly. 2. Carry out the steps: Dismantling Cleaning and inspection Reassembly For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 5 SAFETY REGULATIONS General Instructions Special instructions WARNING! The warning text indicates a risk of personal injury if instructions are not followed. 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. 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. 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.. 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. 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. 1 ! For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

6 – English Displacement Bore Stroke Max. power at Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches TECHNICAL DATA 36 36 38.0 32.0 9000 40 40 40.0 32.0 9000 41 40 40.0 32.0 9000 42 42 42.0 30.0 9300 45 44 42.0 32.0 9000 51 51 45.0 32.0 9000 36 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239 40 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1 41 0.5/ .02 PHELON 0.3/ .012 WALBRO WT 239 42 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98 45 0.5/ .02 PHELON 0.3/ .012 ZAMA C1Q-EL1 51 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170 36 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050 40 33-46/13-18 17.4/8500 rpm .325 1.3/ .050 41 33-46/13-18 17.3/9000 rpm .325-3/8 1.3/ .050 42 28-46/11-18 17.9/9300 rpm .325 1.5/ .058 / 1.3/ .050 1) 45 33-46/13-18 17.4/8500 rpm .325 1.3/ .050 51 33-51/13-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050 1) 1) From May 1996 Bar length Chain speed Chain pitch Drive link gauge cm/inches m/s inches mm/inches For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 7 Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion TECHNICAL DATA 36 3000 4500 13000 RCJ 7 Y 40 2500 3600 12500 RCJ 7 Y 41 3000 4500 13000 RCJ 7 Y 42 2700 3800 14500 RCJ 7 Y 45 2500 3600 12500 RCJ 7 Y 51 2500 3700 12500 RCJ 7 Y 36 0.4 7 0.2 Yes 40 0.5 8 0.25 Yes 41 0.4 7 0.2 Yes 42 0.5 3-7 0.27 Yes 45 0.5 8 0.25 Yes 51 0.6 10 0.3 Yes 36 4.6 5.3 (13") No 40 4.7 5.4 (13") No 41 4.6 5.3 (13") No 42 4.7 5.5 (13") No 45 4.7 5.4 (13") No 51 5.2 6.2 (15") No Weight without bar and chain Weight with bar and chain Handle heater kg kg/lbs Watt/ r/min Idling speed Engagement speed Max. speed Spark plug For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

8 – English Displacement Bore Stroke Max. power at Bar length Chain speed Chain pitch Drive link gauge Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches cm/inches m/s inches mm/inches TECHNICAL DATA 55 53 46.0 32.0 9000 61 62 48.0 34.0 8300 242XP 42 42.0 30.0 9900 246 46 44.0 30.0 9000 254XP 54 45.0 34.0 9300 257 57 46.0 34.0 9000 55 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO WT 170 61 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 254 242XP 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98 246 0.5/ .02 SEM AM 7 0.3/ .012 WALBRO HDA 98 254XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 35B 257 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120 55 38-51/15-20 17.4/9000 rpm .325-3/8 1.5/ .058 / 1.3/ .050 1) 61 38-51/15-20 18.4/8300 rpm 3/8 1.5/ .058 242XP 28-46/11-18 19.1/9900 rpm .325 1.5/ .058 / 1.3/ .050 1) 246 28-46/11-18 17.3/9000 rpm .325 1.5/ .058 / 1.3/ .050 1) 254XP 33-51/13-20 17.3/9300 rpm .325-3/8 1.5/ .058 257 33-51/13-20 17.3/9000 rpm .325-3/8 1.5/ .058 1) From May 1996 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

English – 9 Idling speed Engagement speed Max. speed Spark plug Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump Weight without bar and chain Weight with bar and chain Handle heater Litres cm 3 /min at 8.500 rpm Litres r/min r/min r/min Champion kg kg/lbs Watt/ r/min TECHNICAL DATA 55 2500 3700 12500 RCJ 7 Y 61 2500 3700 12000 RCJ 7 Y 242XP 2700 3900 15500 RCJ 7 Y 246 2700 3900 15000 RCJ 7 Y 254XP 2700 3700 13800 RCJ 7 Y 257 2700 3700 13500 RCJ 7 Y 55 0.6 10 0.3 Yes 61 0.75 4/8/12/17 0.45 Yes 242XP 0.5 3-7 0.27 Yes 246 0.5 3-7 0.27 Yes 254XP 0.6 3-10 0.3 Yes 257 0.6 3-10 0.3 Yes 55 5.2 6.2 (15") No 61 6.1 7.1 (15") No 242XP 4.7 5.5 (13") 65/10.000 246 4.7 5.5 (13") No 254XP 5.4 6.3 (13") 65/10000 257 5.6 6.6 (13") 65/10000 For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

10 – English Displacemennt Bore Stroke Max. power at Bar length Chain speed Chain pitch Drive link gauge Spark plug gap Ignition system Air gap Carburettor cm 3 mm mm r/min mm/inches mm/inches cm/inches m/s inches mm/inches TECHNICAL DATA 262XP 62 48.0 34.0 9600 268 67 50.0 34.0 9000 272XP 72 52.0 34.0 9300 268K 67 50.0 34.0 9000 272K 72 52.0 34.0 9300 272S 72 52.0 34.0 9300 262XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 WALBRO HDA 120 268 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260 272XP 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 260 268K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255 272K 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255 272S 0.5/ .02 ELECTROLUX ET 0.3/ .012 TILLOTSON HS 255 262XP 33-51/13-20 18.5/9600 rpm .325-3/8 1.5/ .058 268 38-51/15-20 18.4/9000 rpm 3/8 1.5/ .058 272XP 38-51/15-20 20.0/9300 rpm 3/8 1.5/ .058 268K - - - - 272K - - - - 272S - - - - For Husqvarna Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

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HUSQVARNA CHAIN SAWS 36 41 40 45 51 55 42 242XP 246 254XP 257 262XP 61 268 272XP 272S 268K 272K 3120XP 394XP 281XP 288XP Workshop Service Manual

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