JONSERED CHAINSAW FACTORY Repair Manual

1 Workshop Manual Chain Saws Contents This manual covers models: 2036/2040 2041/2045/2050 2054/2055 625/630/670 2077/2083 2095 General recommendations 2 1. Safety equipment 3 2. Starter unit 17 3. Electrical system 23 4. Fuel system 35 5. Centrifugal clutch 55 6. Lubrication system 65 7. Cylinder and piston 77 8. Crankshaft and crankcase 93 9. Tools 115 10. Technical data 127 Downloaded from www.Manualslib.com manuals search engine

2 502 51 02-01 General recommendations Keep this in mind: – Do not start the engine without the clutch and clutch drum fitted. – Do not touch hot parts such as the silencer and clutch before they have cooled sufficiently to avoid burn injuries. – Avoid getting petrol on bare skin or in the mouth. – Wipe up spilled oil immediately from the floor to avoid slipping and subsequent injury. – Do not use tools which are worn or fit badly, e.g. nuts and screws. – Never start the engine indoors. Exhaust fumes are toxic! + Always work on a tidy work bench. + Always work methodically to be sure that all parts are correctly assembled and that screws and nuts are tightened. + Use protective cream on your hands. It reduces the risk of infection and enables dirt to be more easily washed off. Prolonged contact with motor oil can be hazardous to health. + Use special tools when so recommended in order to work correctly. Fire hazard Handle petrol with respect since it is highly inflammable. Do not smoke and make sure that there are no naked flames or sparks in the vicinity. Make sure that there is a functioning fire extinguisher in the vicinity. Do not attempt to extinguish a petrol fire with water. Toxic fumes Read the instructions carefully when using cleaning liquids. Make sure that there is adequate ventilation when handling petrol, trichloroethylene and other viscous liquids. The engine exhaust fumes are toxic. Test run the engine only when there is good ventilation, preferably outdoors. Special tools Some work operations in this workshop manual require the use of special tools. In each section where this is appropriate the tool and order number are illustrated. We recommend the use of special tools partly to avoid personal injury and partly to eliminate expensive damage to the components in question. Sealing surfaces and gaskets Make sure that all sealing surfaces are clean and free from the residue of old gaskets. Use a tool which will not damage the sealing surface when cleaning it. Scratches and irregularities are removed with a fine, float cut file. Sealing rings Always replace a sealing ring which has been dismantled. The sensitive sealing lip can easily be damaged and result in poor sealing capacity. The surface which the seal seals must also be completely undamaged. Lubricate the sealing lip with grease before it is fitted and make sure that it is not damaged, e.g. by shoulder and splines on a shaft. Use tape or conical sleeve as protection. It is important that the sealing ring is correctly turned for it to function as intended. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING ! Downloaded from www.Manualslib.com manuals search engine

3 Safety equipment 1 1. Contents Dismantling 4 Disassembly 4 Fitting 6 Dismantling, mod. 2054/2055 7 Fitting, mod. 2054/2055 9 Dismantling, mod. 2077/2083 10 Fitting, mod. 2077/2083 11 Checking of automatic function 12 Checking of brake action 13 Chain catcher 13 Throttle lock 13 Downloaded from www.Manualslib.com manuals search engine

4 Safety equipment 1 ! 505 38 17-05 ! In addition to the chain brake the chain catcher and right-hand guard on the rear handle are also con- sidered part of the chain saw’s safety equipment. It is obviously important that the chain brake functions as intended, but it is also important that the chain catcher is undamaged and in position. In the event of a chain break this will catch up the chain so that the hand will not be injured. WARNING! Protective goggles must be worn during all work on the chain brake to prevent personal injury if for some reason the brake spring should fly off. Dismantling Dismantle the chain brake from the chain saw. Disassembly Release the chain brake. Press out the one half of the hand guard’s bearing. Press out the other half of the hand guard’s bearing. Dismantling Remove the guide bar's attachment nuts and lift off the clutch cover with the chain brake. Clean from sawdust and dirt. WARNING! The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work. Disassembly Release the chain brake. Unscrew the screw to the hand guard’s bearing completely, and then screw in approx. 2 turns. Drive out the bearing by tapping the screw with a hammer. Press out the other half of the bearing by means of suitable mandrel, e.g. 505 38 17-05. Lift off the hand guard. Downloaded from www.Manualslib.com manuals search engine

5 Safety equipment 1 ! Remove the screws and the cover over the brake spring. Bend up the brake spring. Press out the toggle-joint’s bearing pin and lift off the complete brake mechanism. Press out the plate spring with a suitable mandrel. Remove the screws and lift off the cover over the brake spring. WARNING! The brake spring is tensioned and can slip out of its position. Use a screwdriver and carefully bend up the spring. Press out the toggle-joint’s bearing pin by means of a suitable mandrel. Lift off the complete brake mechanism. Press out the plate spring with a suitable mandrel, and replace if necessary. Clench the spring eye with a pair of pliers so that it is easier to fit the new spring. Downloaded from www.Manualslib.com manuals search engine

6 Safety equipment 1 0,8 mm The brake band must have a minimum thickness of 0.8 mm at the most worn point. Remove the screw and replace the brake band. Dismantle the lock-ring and the pin in order to replace the spring inside the hand guard. Assembly Grease the spring and fit it in the hand guard. Check the wear on the brake band. At the most worn point the band must have a thickness of at least 0.8 mm. Otherwise it should be replaced with a new band. Remove the screw and fit a new brake band. Check after fitting that the brake band does not touch the toggle-joint and ob- struct its movement. Inside the hand guard there is a spring which is accessible for replacement after the lock-ring and pin are dismantled. Use a small screwdriver to remove the lock-ring. Assembly Grease the spring and push it in the hand guard as far as it goes. Fit the pin and lock-washer. NOTE! The pin should not go through the eye on the spring. Check that the spring is turned correctly. Downloaded from www.Manualslib.com manuals search engine

7 Safety equipment 1 ! A B Fit the brake mechanism in the clutch cover. Lubricate the bearing points with thin oil. Press down the brake spring by means of a Phillips screwdriver. Fit the cover. Grease the bearing surfaces and fit the hand guard. Check that the brake functions. Dismantling Mod. 2054/2055 Remove the screw, sleeve and washer for the hand guard’s bearing on the starter unit side, including the clutch cover, guide bar and chain. Clean! Place the brake mechanism in position on the clutch cover. Press in the toggle-joint’s bearing pin (A) and place the tubular pin (B) in position. Lubricate the bearing points with thin oil. Press down the brake spring in the clutch cover by means of a Phillips screwdriver. WARNING! Observe care to avoid injury if the screwdriver slips. Fit the cover over the spring mechanism. Grease the bearing points for the hand guard. Press down the hand guard over the bearing and fit both bearing sleeves. NOTE! Check that the bearing sleeves are placed on the correct side. Tension and release the chain brake a number of times to check that it functions. Dismantling Mod. 2054/2055 On these models the chain brake’s hand guard has an extra bearing point on the starter unit side. Remove the screw, sleeve and washer for this bearing. Remove the clutch cover, guide bar and chain. Clean from sawdust and dirt. Downloaded from www.Manualslib.com manuals search engine

8 Safety equipment 1 Dismantle the protective plate over the guide bar attachment and the chain brake. Release the chain brake! Remove the plate clamp over the brake spring and bend away the spring. Remove the lock-ring round the hand guard’s bearing pin and lift off the brake mechanism. Replace the plate insert in the hand guard if the pins are worn by first pressing out the fitted pin. Remove the protective plate over the guide bar attachment. Remove the screws and lift off the chain brake. Release the chain brake! ! WARNING! The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work. Remove the screw and plate clamp over the brake spring. Carefully bend away the spring by means of a screwdriver. NOTE! The spring has a certain tension even when the brake is released, and therefore it should be dismantled carefully. Remove the lock-ring round the hand guard’s bearing pin and lift off the brake mechanism. If the pins on the plate insert in the hand guard are worn the complete insert can easily be replaced. Press out the fitted pin with a suitable mandrel and replace the insert. Downloaded from www.Manualslib.com manuals search engine

9 Safety equipment 1 0,8 mm Dismantle the brake mechanism and replace worn or damaged parts. Fit the brake spring and plate clamp over the spring. Fit the chain brake on the crankcase. Screw tight the cover plate over the guide bar attachment and fit the brake’s bearing on the starter unit side. Dissassemble the brake mechanism and replace worn or damaged parts. The brake band should have a minimum thickness of 0.8 mm at the most worn place. Assembly Mod. 2054/2055 Fit the brake in the reverse order to dismantling. Begin with by fitting the hand guard. Lubricate all moving parts with thin oil. Fit the brake spring by means of a Phillips screwdriver. WARNING! Observe care to avoid injury if the screwdriver slips. ! Fit the plate clamp over the spring. Fit the chain brake on the crankcase. NOTE! Make sure that the guide pin on the brake fits into the hole in the crankcase before the screws are tightened. Fit the cover plate on the guide bar attachment. Screw tight the screw for the brake’s bearing on the starter unit side. Do not forget the washer between the crankcase and brake! Downloaded from www.Manualslib.com manuals search engine

10 Safety equipment 1 ! Dismantling Mod. 2077/2083 Dismantle the chain brake’s bearing on the starter unit side. Remove the clutch cover, guide bar and chain. Clean! Remove the screws and lift off the chain brake. Release the chain brake! Lift up the toggle-joint carefully by means of a screwdriver. Dismantle the hand guard. Press the hand guard out of the bearing. Dismantling Mod. 2077/2083 Remove the screw, sleeve and washer for the chain brake’s bearing on the starter unit side. Remove the clutch cover, guide bar and chain. Clean from sawdust and dirt. Remove the screws and lift off the chain brake. Release the chain brake! ! NOTE! The other end of the spring is controlled by a pin which goes into the centre. For this reason do not try to lift up the spring there. Dismantle the hand guard. Remove the lock-ring by means of a small screwdriver. Hold your thumb over so that the ring does not fly away. Press out the hand guard from the bearing. WARNING! Observe care so that the sprin loaded catch does not fly away. WARNING! The brake spring is tensioned with a very large force and can cause personal injury if the brake is not released prior to further work. Lift up the toggle-joint carefully by means of a screwdriver. Hold your hand over. Downloaded from www.Manualslib.com manuals search engine

JONSERED CHAINSAW FACTORY Repair Manual

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