Workshop manual

445 445e 450e

English
 Contents

Workshop manual
Husqvarna 445, 445e och 450e

Contents
Index........................................................................ 4
Introduction and safety instructions.................... 7
Technical Specifications...................................... 10
Service tools......................................................... 12
Service data.......................................................... 14
Safety equipment................................................. 16
Repair instructions............................................... 24
Carburettor............................................................ 33
Fault tracing.......................................................... 53

Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify
the design and appearance of products without prior notice.

English – 
Index

Index
B M
Bar bolt 52 Muffler 19
Replacing the bar bolt 52 Assembling the muffler 19
C Dismantling the muffler 19
O
Carburettor 33
Assemble on the saw 40 Oil pump and screen 31
Assembly 38 Assembling the oil pump and screen 32
Carburettor adjustment 41 Cleaning and inspection 31
Cleaning and inspection 37 Dismantling the oil pump and screen 31
Design 33 P
Dismantling 35
Function 34 Piston and cylinder 45
Pressure testing the carburettor 39 Assembling the piston and cylinder 47
Centrifugal clutch 30 Cleaning and inspection 45
Assembling the centrifugal clutch 31 Dismantling the piston and cylinder 45
Dismantling the centrifugal clutch 30 Faults and causes 47
Inspection and cleaning 30 Pressure testing the cylinder 49
Chain brake 17 S
Assembling the chaine brake 18 Service data 14
Cleaning and inspection 17 Service tools 12
Dismantling the chaine brake 17 Starter 25, 26
Chain catcher 20 Changing a broken or worn starter cord 26
Replacing the chain catcher 20 Changing a broken return spring 27
Crankcase and crankshaft 50 Cleaning and inspection 25, 26
Assembling the complete crankshaft 51 Dismantling the starter unit 25
Changing the crankshaft bearing 50 Starter unit assembly 27
Dismantling the crankcase and crankshaft 50 Stopping function 21
F Resistance measurement - stop function 21
Fuel system 44 Stop switch 20
Replacing the fuel filter 44 Assembling the stop switch 21
Replacing the fuel hose 44 Cleaning and inspection 20
Dismantling the stop switch 20
I Symbols
Ignition module and flywheel 28 Symbols in the Workshop Manual 9
Assembling the ignition Symbols on the saw 9
module and flywheel 29 T
Cleaning and inspection 28
Dismantling the ignition Tank unit 42
module and flywheel 28 Assembly 43
Testing the ignition module 27 Dismantling 42
Intake system 32 Tank valve 42
Assembling the intake system 32, 48 Cleaning and inspection 42
Cleaning and inspection 32 Technical Data 10
Dismantling the intake system 32 Threads 51
Introduction and safety instructions 7 Repairing damaged threads 51
General 7 Throttle trigger lock,
General Instructions 8 throttle trigger and spring 22
Modifications 7 Assembling the throttle trigger lock, throttle
Numbering 7 trigger and spring 23
Safety 7 Cleaning and inspection 23
Special Instructions 8 Dismantling the throttle trigger lock, throttle
Structure 7 trigger and spring 22
Target group 7 Trouble shooting 54
Tools 7 Trouble-shooting methods 55

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 Index

V
Vibration damping system 43
Assembly 43
Cleaning and inspection 43
Dismantling 43

English – 
Introduction and safety instructions

2 Introduction and safety instructions

Contents
2.1 General . ..........................................................................................................................7
2.2 Security ...........................................................................................................................7
2.3 Target group ....................................................................................................................7
2.4 Changes...........................................................................................................................7
2.5 Tools ................................................................................................................................7
2.6 Structure ..........................................................................................................................7
2.7 Numbering .......................................................................................................................7
2.8 General instructions ........................................................................................................8
2.9 Special instructions .........................................................................................................8
2.10 Symbols on the saw ........................................................................................................9
2.11 Symbols in the Workshop Manual ...................................................................................9

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 Introduction and safety instructions

2 Introduction and safety instructions

2.1 General 2.6 Structure
This Workshop Manual describes in detail how the This Workshop Manual can be used in two diffe-
chain saw is to be fault traced, repaired and tested. rent ways:
A description of different safety measures that
should be taken during repair work is also given. • For the repair of a particular system on the
chain saw.
2.2 Safety • Dismantling and assembly of the entire chain
Note! The section dealing with safety must be saw.
read and understood by all those carrying out
repair work or service on the chain saw. Repair of a specific system
When a particular system on the chain saw is to be
Warning symbols can be found in this Workshop repaired, proceed as follows:
Manual and on the chain saw. See “Symbols on
the saw” and “Symbols in the Workshop Manual”. A 1. Look up the page for the system in question.
new decal must be applied as soon as possible if a
warning symbol on the chain saw has been da- 2. Carry out the sections: Dismantling
maged or is missing so that the greatest possible Cleaning and inspection
safety can be obtained when using the chain saw.
Assembling
2.3 Target group
Dismantling and assembling the entire chain saw
This Workshop Manual is written for personnel with
Proceed as follows when the entire chain saw is to
general knowledge about the repair and service of
be dismantled and assembled:
chain saws.
1. Look up the chapter “Repair instructions”,
The Workshop Manual must be read and under-
which deals with the Starter and carry out the
stood by personnel who will carry out repair work
instructions set out under Dismantling.
and service on the chain saw. The Manual is also
suitable for use when training new employees. 2. Work forward in the Manual and carry out Dis-
mantling in the order set out in the sections.
2.4 Changes 3. Go back to the Starter and carry out the in-
Modifications will be successively introduced on structions under Cleaning and Inspection.
the chain saw during production. When these 4. Work forward in the Manual and carry out
modifications affect the service and/or spare parts, Cleaning and Inspection in the order set out
separate service information will be sent out on in the sections.
each occasion. This means that in time this Work-
5. Order or take out all requisite spare parts from
shop Manual will become out of date. In order to
the stores.
prevent this, the Manual should be read together
with all service information concerning the chain 6. Look up the chapter “Repair instructions” which
saw in question. deals with the Crankcase and carry out the
instructions set out under Assembling.
2.5 Tools 7. Work back in the Manual and carry out As-
Special tools are required for some stages. All sembling in the order set out in the sections.
service tools are listed in the Workshop Manual.
Usage is evident from respective sections. Some sections include a Description of the actual
unit in order to increase the basic understanding.
Always use Husqvarna’s original:
• Spare parts 2.7 Numbering
• Service tools Position references to components inside the figu-
• Accessories res are designated A, B, etc.
The figures are numbered 1, 2 etc.
The position references and figure numbers restart
in each new section.

English – 
Introduction and safety instructions

2.8 General instructions 2.9 Special instructions

The workshop where chain saw repairs are to be The fuel that is used in a chainsaw poses the fol-
done must be equipped with safety equipment as lowing hazards:
set out in local provisions.
• The fuel and its fumes are toxic.
No one may repair the chain saw unless they have
• May cause irritation to skin or eyes.
read and understood the content of this Workshop
Manual. • May cause breathing difficulties.
• Highly flammable.
In this workshop manual the following boxes indi-
cate where caution should be taken.
When using compressed air the air jet should
never be pointed at the body. Air can be forced into
WARNING!
the bloodstream and cause fatal injury.
The warning text warns of the risk
of personal injury if the instruc-
Wear ear protection when testing saws.
tions are not followed.
After testing a saw do not touch the silencer until
it has cooled down. The silencer gets very hot and
NOTE!
you may burn yourself. Wear protective gloves
The warning text warns of the risk of ma- when working on the silencer.
terial damage if the instructions are not
followed. The guide bar, chain and clutch cover (chain brake)
must be fitted before the saw is started. If not, the
clutch may come loose and cause injury.

Poor chain lubrication can result in failure of the

chain, which could cause serious or fatal injury.

Take care to ensure that the spring inside the

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
fly out and cause injury.

Before removing the tensioning spring from the

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

tested, see “Chain brake – reassembly \ Operating
test”.

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.

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 Introduction and safety instructions

2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual

The symbols below are embedded on the chain
saw.

Choke Lever This symbol warns of personal injury

when the instructions are not followed

Refuelling

Stop button

Screw for adjusting chain lubri-

cation

Filling with chain oil

English – 
Technical data

3 Technical data

Displacement Cylinder bore Stroke Max power/speed

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

445/e: 45,7 / 2,78 42 / 1,65 33 / 1,30 2,0 / 2,7 / 9 000

450e: 50,2 / 3,06 44 / 1,73 33 / 1,30 2,4 / 3,2 / 9 000

Spark plug gap Ignition system Air gap Carburettor type

mm/inches mm/inches

445/e: 0,5 / 0,02 Walbro MBU-16 0,3 / 0,012 Zama EL37 C1M
450e: 0,5 / 0,02 Walbro MBU-16 0,3 / 0,012 Zama EL37 C1M

Effective cutting length Chain speed at Chain pitch Drive link

cm/inches max power – revs mm/inches mm/inches
m/s - r/min

445/e: 31-50 / 13-20 17,3 / 9 000 8,25 / 0,325 1,3 / 0,050 - 1,5 / 0,058
450e: 31-50 / 13-20 17,3 / 9 000 8,25 / 0,325 1,3 / 0,050 - 1,5 / 0,058

10 – English
 Technical data

rpm

Idling speed Engagement speed Spark plug

rpm rpm

445/e: 2 700 3 800 NGK BPMR 7A

Champion RCJ 7Y
450e: 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

445/e: 0,45 / 0,95 9 0,26 / 0,55 Yes

450e: 0,45 / 0,95 9 0,26 / 0,55 Yes

Weight without Weight with

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

445/e: 4,9 / 10,8 6,2 / 13,6

450e: 5,1 / 11,2 6,2 / 13,6

English – 11
Special tools

4 Special tools
1 2 3

4 5 6 7

M5 M5
M6

8 9

10 11

12 – English
 Special tools

12 13a 14
13b

15
16b 16c
17

16a

18

Item Description Used for Order no.

1 Clutch tool Centrifugal clutch 502 54 16-03
2 Piston stop Locking the crankshaft 502 54 15-01
3 Fuel filter hook Withdrawing the fuel filter 502 50 83-01
4 Allen key For M5 bolts 502 50 87-01
5 Allen key For M6 bolts 502 50 64-01
6 Pressure tester Pressure testing cylinder 503 84 40-02
7 Feeler gauge Adjusting ignition module 502 51 34-02
8 Assembly fixture Assembling chain saw 502 51 02-01
9 Pressure gauge Pressurisation during testing 531 03 06-23
10 Test spark plug Checking the ignition module 501 97 64-01
11 Rev counter Adjusting carburettor 502 71 14-01
12 Assembly pliers Fitting spark plug guard 502 50 06-01
13a Cover plate, exhaust Sealing the exhaust port 502 54 11-02
13b Cover plates, inlet Sealing the intake manifold 501 32 35-01
14 Assembly tool Assembling spring, chain brake 502 50 67-01
15 Puller Pulling bearing of crankshaft 504 90 90-01
16a Sleeve Fitting crankshaft 502 50 30-18
16b Shaft extension Flywheel side 502 50 30-18
16c Shaft extension Cluch side 502 50 30-18
17 Punch Dismantling the flywheel 502 51 94-01
18 Adjustment screwdriver Adjustment of the carburettor 530 03 55-60

English – 13
Service data

5 Service data

1Nm 1mm
20Nm 19mm

2Nm 4mm

14Nm 4mm

1Nm 5mm

5.5Nm 4mm

1.5Nm

20Nm

1.5Nm

1.5Nm

14 – English
 Service data

7Nm 4mm

,5Nm 4mm

5Nm 4mm
1,5Nm
Nm 4mm 2Nm 1mm

8Nm 4mm

,5Nm 4mm
,5Nm 4mm

2.5Nm 4mm

,5Nm 5mm
,5Nm 5mm

1,5Nm

Nm

,5Nm 4mm

,5Nm 4mm

English – 15
Safety equipment

6 Safety equipment
Contents
6.1 Dismantling the chain brake ............................................................................................17
6.2 Assembling the chain brake ............................................................................................18
6.3 Dismantling the muffler . ..................................................................................................19
6.4 Assembling the muffler ....................................................................................................19
6.5 Replacing the chain catcher ............................................................................................20
6.6 Dismantling the stop control ............................................................................................20
6.7 Resistance measurement - stop function ........................................................................21
6.8 Assembling the choke/stop control ..................................................................................21
6.9 Dismantling the throttle lock, throttle control and spring . ................................................22
6.10 Assembling the throttle lock, throttle control and spring ..................................................23

16 – English
 Safety equipment

6 Safety equipment
6.1 Dismantling the chain brake

1
Release the brake by moving the front hand guard
backward.
Loosen the bar nuts and remove the clutch cover,
chain and bar. (see figure 1)

Fig 1

2
Carefully tighten the clutch housing in a vice.
Release the brake by using the saw's front hand
guard (A) as a tool. Mesh with the brake and tigh-
ten anti-clockwise until the brake is activated. (see
figure 2)
WARNING!
Exercise care to ensure the spring
does not fly out and cause perso-
nal injury. Wear protective glasses.
Fig 2

3
Loosen the screws and carefully remove the cover
over the brake spring. (see figure 3)

Fig 3

4
Hold one hand over the brake spring; press a nar-
row screwdriver in between the rear section of the
spring and the clutch cover. Carefully pry upward
until the spring releases and runs onto the screw-
driver shaft. (see figure 4)

Fig 4
Cleaning and inspection
• Carefully clean and check all parts. Parts must
be replaced if cracked or show signs of other
defects. Always use original spare parts. min 0,6 mm

• Measure the thickness of the chain brake band.

It must not be less than 0.6 mm at any point.
(see figure 5)
• Lubricate the knee joint with grease.

Fig 5

English – 17
Safety equipment

6.2 Chain brake – reassembly

1
Bolt the elbow joint to the brake band (see figure 5)
and tighten to a torque of 1–1.5 Nm.
Locate the elbow joint and connected brake band
in their recesses in the clutch cover. Lubricate the
recess for the spring with grease. (see figure 6)

Secure the circlip (A) (see figure 6)

Fig 6

2
Grip the clutch cover in a vice. Compress the
spring with special tool 502 50 67-01 and push it
down with your thumb. (see figure 7)

WARNING!
Make sure the spring does not fly
out and cause injury. Wear eye
protection.

Fig 7

3
Fit the cover over the chain brake spring, tighten-
ing the screws to a torque of 1–1.5 Nm. (see figure
8)

Fig 8

4
Tension the brake spring by using the kickback
guard from the saw as a tool. Engage it with the
brake mechanism and turn clockwise to release
the brake. (see figure 9)

5
Turn the chain tensioner anticlockwise as far as it
will go.

Refit:
• guide bar Fig 9
• chain
• clutch cover

NOTE!
After completing the repair the chain
brake must be tested as described below.

18 – English
 Safety equipment

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
fall towards the surface.
Fig 10
• When the guide bar hits the surface the chain
brake must engage. (see figure 10)
6.3 Silencer – removal

WARNING!
Do not touch the silencer until it
has cooled down, otherwise you
may burn yourself.

1
Remove the cylinder cover, silencer, gasket and A
cooling plate.

2
If the saw is fitted with a spark arrestor mesh (A) Fig 11
this must also be removed. (see figure 11)

Cleaning and inspection

Clean and inspect all parts carefully. If there are
any cracks or other defects replace the damaged
parts with new ones.
The spark arrestor mesh is best cleaned with a
wire brush. If the mesh is damaged it must be
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.

6.4 Silencer – refitting

1
If the saw is equipped with a spark arrestor mesh
this should be fitted first.

2
Refit
• 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 12–14 Nm.

English – 19
Safety equipment

6.5 Chain catcher – replacement

If the chain catcher is worn it must be replaced with
a new one.

1
Release the brake by pushing the kickback guard
backwards. Undo the guide bar bolts and remove
the clutch cover, chain and guide bar.

2
Remove the chain catcher and replace it with a
new one. Check that the vibration damping spring Fig 12
locates correctly against the crankcase when you
bolt the new chain catcher in position. (see figure
12)
6.6 Dismantling the choke/stop control
1
Remove the cylinder cover and air filter.

2
Loosen the screws (A) (see figure 13)

3
Loosen the filter holder from the rubber mountings
(B). (see figure 13)

4
Cut off the starlock washer and pull out the control
from the shaft on the filter holder.(see figure 14)

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.
Fig 13

Assembly
Secure the rubber mountings.

Replacing the bimetal, see 7.15 Carburettor

Fig 14

20 – English
 Safety equipment

6.7 Stop switch – resistance

measurement

Clean the mating surfaces and check the resis-

tance as follows:

Measure the resistance by connecting a multimeter

to the ignition coil. NOTE! The switch must be in
the “on” (A) position to give the correct reading.
(see figure 15)

The resistance must not be higher than 0.5 Ω when

the switch is in the on position.
Fig 15
The stop switch is in the on-position when the
button is held down (A) (see figure 15) and in the
off-position the button is neutral (B). (See figure 16)

Fig 16

6.8 Assembling the choke/stop control

1
Fit a new control and new starlock washer.

2
Secure the carburettor assembly in the rubber
mounting.

English – 21
Safety equipment

6.9 Throttle lock, throttle trigger and

return spring – removal
1
Loosen the throttle cable on the carburettor, the A
fuel hose and suction hose to the fuel pump.

2
Dismantle the tank unit from the engine unit by
loosening the screws A and E (see figure 17)

Fig 17 A 2xE A
3
Dismantle the handle insert (B) by loosening the B
screw C on the handle. (see figure 18)

Fig 18

4
Press out the throttle control pin (D) with the help
of a punch. (see figure 19)
D

Fig 19

5
Loosen the throttle lock as illustrated with the help
of a screwdriver or the like. Then dismantle from
the shaft in the handle. (see figure 20)

6
Dismantle throttle cable and throttle control.

Fig 20

22 – English
 Safety equipment

7
Now loosen the spring.
A
C
Cleaning and inspection D
• Clean and inspect all parts carefully. If there are
any cracks or other defects replace the dama-
ged parts with new ones. Always use original
B
parts.
Fig 21
• Check that the spring is not broken and has not
lost its tension.

6.10 Throttle lock, throttle trigger and

return spring – refitting
1
Lubricate all pins and mating surfaces with a light
oil.
Fig 22
2
Fit the throttle cable (A), throttle control (B) and
spring (C). (see figure 22)
E
3
Hold the spring and insert the throttle lock into the
cut-out in the handle. (see figure 23)

4
Check that the throttle cable casing is in the right
Fig 23
position in the petrol tank. Press in the casing until
it stops. (see figure 23)

5
Fit the throttle control pin (E) with the help of a
punch. (see figure 24)

6
Fit the throttle lock (D) by pressing it onto the shaft
in the handle. (see figure 25)

Fig 24

7
Assemble the handle insert using a screw, when
the throttle control, lever, throttle cable and throttle
D
control lock with pin are fitted correctly. (see figure
25)

Fig 25

English – 23
Repair instructions

7 Repair instructions
Contents
7.1 Dismantling the starter ....................................................................................................25
7.2 Changing a broken or worn starter cord ..........................................................................26
7.3 Tensioning the return spring ............................................................................................26
7.4 Changing a broken return spring .....................................................................................27
7.5 Assembling the starter unit ..............................................................................................27
7.6 Testing the ignition module ..............................................................................................27
7.7 Dismantling the ignition module and flywheel .................................................................28
7.8 Assembling the ignition module and flywheel ..................................................................29
7.9 Dismantling the centrifugal clutch . ..................................................................................30
7.10 Assembling the centrifugal clutch ....................................................................................31
7.11 Dismantling the oil pump and screen ..............................................................................31
7.12 Assembling the oil pump and screen . .............................................................................32
7.13 Dismantling the intake system . .......................................................................................32
7.14 Assembling the intake system .........................................................................................32
7.15 Carburettor ......................................................................................................................33
7.16 Tank unit ..........................................................................................................................42
7.17 Venting the fuel tank ........................................................................................................42
7.18 Vibration damping system ...............................................................................................43
7.19 Replacing the fuel filter ....................................................................................................44
7.20 Changing the fuel hose ...................................................................................................44
7.21 Replacing the air-purge....................................................................................................44
7.22 Dismantling the piston and cylinder . ...............................................................................45
7.23 Assembling the piston and cylinder .................................................................................47
7.24 Pressure testing the cylinder ...........................................................................................49
7.25 Dismantling the crankcase and crankshaft . ....................................................................50
7.26 Replacing the crankshaft bearing ....................................................................................50
7.27 Assembling the complete crankshaft ...............................................................................51
7.28 Repairing damaged threads ............................................................................................51
7.29 Replacing the bar bolt .....................................................................................................52

24 – English
 Repair instructions

7 Repair instructions
7.1 Starter assembly – removal
1
Undo the four bolts that fasten the starter assembly
to the crankcase and lift off the starter assembly.
(see figure 1)

Fig 1

2
Pull out about 30 cm of the cord and fasten it in the 1 2
notch in the pulley rim. Release the tension in the
return spring by letting the pulley wind backwards
slowly. (see figure 2)

WARNING!
If the recoil spring is still under
tension when the pulley is re-
moved it can fly out and cause
injury. Wear eye protection.
Fig 2

3
Remove the bolt from the centre of the pulley and
lift off the pulley. (see figure 3)

Cleaning and inspection

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

Fig 3

English – 25
Repair instructions

7.2 Changing a broken or worn starter

cord
When the starter cord is worn and must be replaced,
the tension on the return spring must be released.

1
Pull the cord out about 30 cm and lift it into the
notch on the outside of the starter pulley. Release
the tension on the return spring by allowing the
starter pulley to rotate slowly backwards.(see
figure 2)

WARNING!
If the spring tension is activated
on the starter pulley, the spring
can fly out and cause personal
injury. Wear protective glasses.
2
Undo the bolt in the centre of the pulley and re-
move the pulley. (see figure 3)
3
Fit a new cord through the hole in the pulley and tie
a knot to secure it. Feed the other end of the cord
through the hole in the starter housing and through
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.

Cleaning and inspection

• Clean and inspect all parts carefully. If there
are any cracks or other defects replace the
damaged parts with new ones. Lubricate the
return spring with a little grease.

7.3 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. (see figure 4)
Fig 4
2
Tension the cord with the handle. Remove the
thumb and released back the cord (see figure 5)

Fig 5

26 – English
 Repair instructions

7.4 Replacing a worn recoil spring

WARNING!
Make sure the recoil spring does
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”.

7.5 Starter assembly – refitting

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

Fig 6

7.6 Ignition module – testing

If there is a fault in the ignition system the ignition
module must be tested before the ignition system
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 cylinder.
Fig 7
• Turn the engine over using the starter cord.
• If the test spark plug produces a spark the
ignition module is OK. (see figure 7)

English – 27
Repair instructions

7.7 Ignition module/flywheel – removal

1
A
Remove the cylinder cover. Disconnect the HT lead,
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. (see
figure 8)

Fig 8

2
If replacing the ignition module (B), loosen the C
cable lug (C) and screw (A) and unscrew it. The
ignition module can be left in place if you are simply
removing the flywheel. (see figure 9)
D

3
Loosen the flywheel nut (E) using a suitable socket
and remove it.(see figure 10) A B
When replacing the cables, they are fitted on the
stop switch. as shown in figure. (see figure 9)

Fig 9

4
Knock on the punch using a metal mallet until
the flywheel releases from the shaft. Remove the
punch and the flywheel. (see figure 10)

Cleaning and inspection

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

Fig 10

28 – English
 Repair instructions

7.8 Ignition module and flywheel

– refitting
1
Fit the flywheel on the crankshaft journal. Turn the
flywheel so that the key lines up with the keyway in
the shaft.

Fit the nut on the shaft and tighten to a torque of

25-30 Nm. (see figure 11)
Fig 11

2
To refit the ignition module proceed as follows: A
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- 02) held in position
at the same time, without tightening the bolts. Fit the
earth cable (black) (A). Set a distance of 0.3 +/- 0.1
mm, between the ignition module and magnet. The
measurement applies to the two lowest lugs on
the ignition module. Tighten the screws, tightening Air gap tool
torque 4.5–6 Nm. Fit the blue cable on the ignition
module. (see figure 12)
Fig 12
3
Then refit:
• cable guide and press the leads into position
• HT lead
• starter assembly, tighten to a torque of 2.5–3.5
Nm
• cylinder cover

When replacing the cables, they are fitted on the

stop switch as shown in middle figure on the pre-
vious page.

English – 29
Repair instructions

7.9 Centrifugal clutch – removal

1
Remove the cylinder cover. Disengage the chain
brake by pushing the kickback guard backwards.
Undo the bar nut and remove the clutch cover, bar
and chain. (see figure 13)

2
Disconnect the HT lead. Remove the spark plug
and fit piston stop 502 54 15-01 (A) in its place.
(see figure 14)
Fig 13

3
Unbolt the clutch using tool 502 54 16-03 (B) and
a suitable socket or wrench. Turn the clutch clock-
wise to remove it. (see figure 15)

Fig 14

4
Secure the clutch in a vice as shown in figure. Ca-
refully release the clutch springs using circlip pliers B
(C) (see figure 16)

NOTE!
Handle the clutch springs carefully. If they
are opened up too much they could dam-
age the saw.

Fig 15

Inspection and cleaning

• 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. C
• 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.
(see figure 16)

Min 65mm
Fig 16

30 – English
 Repair instructions

7.10 Centrifugal clutch – refitting

1
Insert the clutch springs in the shoes using circlip
pliers.
2
Screw the clutch (anti-clockwise) until it stops.
Now tighten using tool 502 54 16-03 and a suitable
socket wrench or combination spanner. Tightening
torque min. 20 Nm.
.
3
Remove the piston stop. Fit the spark plug, tightening
A
it to a torque of 20 Nm, then connect the HT lead.
B
Then refit:
• cylinder cover
• guide bar C
D
• chain
• clutch cover
Fig 17

7.11 Dismantling the oil pump and

screen
1
Empty and clean the oil tank.

Remove the cylinder cover. Release the brake by

moving the front hand guard backward. Undo the
bar nut and remove the clutch cover, bar and chain.
Loosen spark plug cap and remove the spark plug,
fit the piston stop 502 54 15-01. Loosen the clutch
(clockwise) using tool 502 54 16-03 and a suitable Fig 18
socket wrench or combination spanner.
2
Remove the centrifugal clutch (A). Remove the
clutch drum (B), needle bearing (C) and pump
drive wheel (D).(see figure 17)

3
Unscrew the chain guide plate. (see figure 18)

4 E
Unbolt the oil pump from the crankcase and
remove it together with the oil pressure hose. (see
figure 19) Fig 19

5
The oil pump (E) is not adjustable. (see figure 20) E
Cleaning and inspection
• Clean and inspect all parts carefully. If there are
any cracks or other defects replace the dama-
ged parts with new ones. Always use original
parts.
• Lubricate all moving parts with chain oil.
Fig 20

English – 31
Repair instructions

7.12 Assembling the oil pump and screen 7.14 Assembling the intake system
1 1
Fit the chain guide plate with tightening torque Assemble the carburettor flange and air flange
1–1.5 Nm. on the intake bellows. Now assemble the intake
bellows and the partition on the cylinder using tool
Fit the drive gear, needle bearing, clutch drum and 502 50 87-01. (see figure 21)
the clutch (min. 20 Nm).

Fit the chain, bar and clutch cover.

WARNING! Cleaning and inspection

Poor chain lubrication can result Clean and check all parts carefully. Parts must be
in failure of the chain, which could replaced if cracked or show signs of other defects.
cause serious or fatal injury. Always use original spare parts.

7.13 Air intake system – removal

The air intake system comprises:
• intake manifold (A)
• insulating plate (B)
• air flange (C)
• carburettor flange (D)
(see figure 21)
1
Loosen the throttle cable from the bracket on the
carburettor flange.

2
Now loosen the screws using tool 502 50 87-01..

Fig 21
D

32 – English
 Repair instructions

7.15 Carburettor
WARNING!
The fuel used in the chainsaw has
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 not A
correspond with the carburettor on the chainsaw.
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. Fig 22

The jets and the fuel’s control functions are located

in the metering unit (A). Here the correct quantity
of fuel is adjusted for the actual speed and power
output. (see figure 22)

The mixing venturi (B) houses the choke, throttle

valve and diffuser jets. Here air is mixed with the
fuel to give a fuel/air mixture that can be ignited by B
the ignition spark. (see figure 23)

Fig 23

In the pump unit (C), fuel is pumped from the fuel

tank to the metering unit. One side of the pump di-
aphragm is connected to the crankcase and pulses
in time with the pressure changes in the crankcase.
The other side of the diaphragm pumps the fuel.
(see figure 24)

C
Fig 24

English – 33
Repair instructions

Function
The carburettor operates differently in the following
modes: J

• Cold start mode

• Idling mode D E F G
• Part throttle mode
• Full throttle mode
H
In the cold start mode (see figure) the choke valve I
(H) is fully closed. This increases the vacuum in
the carburettor so that fuel is sucked more easily
from all the diffuser jets (D, E and F). The throttle Fig 25
valve (I) is partly open. Extra air inlet (J) is closed.
(see figure 25)

In the idling mode (see figure) the throttle valve (I

and J) is closed and the choke valve (H) is open.
J
Air is sucked in through an aperture in the throttle
D
valve and a small amount of fuel is supplied th-
rough the diffuser jet (D). (see figure 26)

H
I

Fig 26

In the part throttle mode (see figure below) the th-

rottle valve (I) is partially open and the choke valve
(H) is open. Fuel is supplied through the diffuser
jets (D and E). The throttle valve (J) starts to open.
(see figure 27)
D E

I H

Fig 27

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
opened. (see figure 28) J

D E F G

I H

Fig 28

34 – English
 Repair instructions

Dismantling the carburettor

1. Dismantle the cylinder cover and the air filter.
2. Loosen the bolts (A).
3. Loosen the filter holder from the rubber moun-
tings (B).
(see figure 29)

Fig 29

4. Loosen the suction hose (C) and return hose

(G) from the fuel pump.
5. Dismantle the air shutter (D).
6. Dismantle the throttle cable (E).
7. Loosen the fuel hose (F).
(see figure 30)

Fig 30

English – 35
Repair instructions

8. Dismantle the cover (A) on the metering unit

and carefully remove the control diaphragm (B)
with gasket.
A
9. Dismantle the screw (F) and lift out the jet
valve (E) with lever (D), shaft (G) and spring
(H).
B
10. Dismantle the cover (K) on the pump unit
and carefully remove the gasket (L) and di- D
aphragms (M). G
C

11. Use a needle or the like and carefully remove F E

the fuel screen (J). H

12. Dismantle the high (N) and low jet screws.(P)

13. If necessary remove the throttle and choke val-

ves, also dismantle the shafts with lever arms
and springs.
(see figure 31)

N
P
J

Fig 31

36 – English
 Repair instructions

Cleaning and inspection 5. That the tips of the high (N) and low jet screws
Clean all units in clean petrol. (P) are not damaged. (see figure 31)
6. That the intake manifold is undamaged.
Use compressed air to dry the petrol on the com-
ponents. Direct the air through all channels in the 7. The carburettor has an extra air shutter con-
carburettor housing and ensure that they are not nected in parallel with the ordinary throttle
blocked. Check the following: valve. This is attached to the air flange using
two screws.
1. That gaskets, pump and control diaphragms
are undamaged.
2. That there is no play on the throttle and choke
valve shafts.
3. That the needle valve (D) and its lever (E) are
not worn. (see figure 31)
4. That the fuel screen (J) is whole and clean.
(see figure 31).

Fig 32

English – 37
Repair instructions

Assembly
Maintain a high level of cleanliness when assem-
bling the carburettor. The slightest contamination
can result in running problems.

1. If the throttle and choke valves, together with

levers and springs were removed, they should
be refitted. The spring is tensioned 1-2 turns.
J
Lubricate the shaft bearings with light oil.
M
2. Fit the high and low speed needles and
springs.Note! Do not fully tighten the screws.
This will damage the seats and needle tips.
L
3. Fit the fuel filter (J) by using the handle of a
small screwdriver. (see figure 33)
4. Fit the pump diaphragm (M), gasket (L) and K
cover (K) on the pump unit. (see figure 33)

Fig 33

5. Fit the needle valve (E) with lever (D), pin and
spring and tighten the screw (F). Fit welch plug
(Q) (see figure 34).

Fig 34

6. Check using a ruler or the like that the lever

is level with the assembly plane on the cover.
The lever arm can be bent if necessary. (see
figure 35)

Fig 35

7. Fit the control diaphragm (B) with gasket (C)

and cover (A) on the metering unit. (see figure
36)
8. Fit the throttle valve (U) on the shaft (R). Fit
lever (S) on the shaft (R) parallel with the
ordinary throttle valve. The valve housing (T)
is secured in the air flange using two screws.
(see figure 32)
9. Carry out a pressure test.

Fig 36

38 – English
 Repair instructions

Pressure testing the carburettor

Pressure testing should be carried out with the car-
burettor fully assembled. Testing should always be
carried out after the carburettor has been repaired,
but it can also be carried out as trouble shooting
before dismantling the carburettor.

See figure and carry out the test as follows:

1
Set the high and low jet screws two turns from
the bottom.
Fig 37
2
Connect pressure tester to the carburettor’s fuel
intake.

3
Lower the carburettor into a beaker of water. (see
figure 37)

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 B
Replacing the bimetal
1
Release the locking sleeve (A) using a screwdriver.
(see figure 38)

2
Dismantle the bimetal (B). (see figure 38) A

3
Fit the new bimetal. Ensure that it is seated correc-
tly. (see figure 39)

4
Assembling the locking sleeve. (A) (see figure 38)
Fig 38

Fig 39

English – 39
Repair instructions

Assemble on the saw

1. Assemble the fuel pump and suction hose on
the carburettor.

2. Assemble the fuel hose. (F)

3. Position the carburettor.

4. Fit the return hose (G) on the fuel pump.

5. Fit the throttle cable. (E)

(see figure 40)
Fig 40

6. Assemble the filter holder in the rubber moun-

tings. (B)

7. Snap the purge into the filter holder.

8. Secure the screws. (A)

(see figure 41)

9. Assemble the air filter and cylinder cover.

Fig 41

40 – English
 Repair instructions

Carburettor adjustment
Conditions during adjustment
• The air filter should be clean and the cylinder
cover fitted when adjustments are made. Ad-
justing 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.
• Mount, for this model, approved bar and
chain combination (see Technical data in the Fig 42
Operator's Manual).
445/e 16"
450e 16"
• The chain should not be tensioned more than
that it remains ~ 0,2 inches to the bar.
(see figure 42)

Replacement of the H-needle or complete car-

burettor
1. Carefully screw the new H-needle to the bot-
tom and turn it anticlockwise ”A” turns.
445/e A=2
450e A=2
2. Start the engine. If necessary, adjust the idling
speed with the T-screw until the chain stops.
3. Adjust the H-needle to give a top speed of ”B”
rpm. Use a tachometer.
445/e B = 12500 -13 000, speed limitation
450e B = 12500-13 000, speed limitation
Use screwdriver 530 03 55-60.

4. Let the engine run at ”B” rpm ~ 1 minute, until

warm.
Fig 43
Replacement of the L-needle
1. Screw the new L-needle to the bottom and
then turn it counterclockwise ”D” turns.
445/e D=2
450e D=2

(see figure 43)

English – 41
Repair instructions

7.16 Tank unit

WARNING!
The fuel used in the chain saw has
the following hazardous properties:
1. The fluid and its vapour are
poisonous.
2. Can cause skin irritation.
3. Is highly inflammable.
Dismantling
1. Drain the fuel from the tank.
2. Dismantle the cylinder cover, bar and chain.
See the Operator's Manual.
3. Unhook the throttle cable (G) from the carbu-
rettor. (see figure 44)
4. Dismantle the fuel hose (B) and the fuel pump
return hose (D). (see figure 44)
5. Remove the screws. (A and E). Loosen the
handle. (see figure 45)
6. Dismantle the fuel tank.
Fig 44
7. If necessary, pull-out the fuel hose and pull off
the fuel filter. (see figure 46)
NOTE!
Exercise care so that the fuel hose and
throttle cable are not damaged.
A
7.17 Venting the fuel tank
The two-way valve (C) has the following properties:
(see figure 46)
• Controlled opening pressure in both directions,
which prevents a positive pressure or a vacuum
developing in the fuel tank and impairing engine
performance. This also prevents fuel leakage. A 2xE A
Fig 45
• Opening pressure outward 100–450 mbar.
• Opening pressure inward (vacuum) max.
70 mbar. (2 positions)
Test
Opening pressure outward:
1. Open the filler cap and let the cap remain open
during the entire test. Drain the fuel from the
tank.
2. Connect the pump, ref. no. 531 03 06-23, to
the tank valve. (C)
3. Switch the pump to vacuum mode.
4. Pump 3 times.
5. After pumping the indicator should be between
10–45 kPa.
Opening pressure inward:
1. Open the filler cap and let the cap remain open
during the entire test. Drain the fuel from the
tank.
2. Connect the pump, ref. no. 531 03 06-23, to
the tank valve. (C) Fig 46

3. Switch the pump to pressure mode.

42 – English
 Repair instructions

4. Pump 3 times.
5. After pumping the indicator should stop at max.
7 kPa.

Assembly
1. If the throttle lock has been removed, this must
be assembled before the tank unit and engine
unit are assembled.
2. Lift the engine unit above the tank unit and in-
sert the fuel hoses (in J), return hose (in H)and
throttle cable (in G) in the bottom of the carbu-
rettor compartment. (see figure 47)
3. Fit the handle with the screws (A and E). Tigh-
ten the screws with the torque set out in the
service data (see figure 45) Fig 47

4. Fit the fuel hose (B) and fuel pump return hose
(D) on the carburettor. (see figure 44)
5 Insert the throttle cable casing into the carbu-
rettor flange bracket and hook on the throttle
cable (G) (see figure 44)
6 Assemble the cylinder cover, bar and chain.
See the Operator's Manual.

7.18 Vibration damping system

Dismantling
1. Dismantle the following parts:
• Bar and chain. See the Operator's Manual.
• Cylinder cover. See the Operator's Manual.
• Tank unit and handle.
2. Dismantle the spring on the cylinder with the Fig 48
help of a 4 mm allen key. (see figure 48)
3. Dismantle the springs on the tank unit with the
help of a 4 mm allen key. (tool 502 50 87-01)
(see figure 49)
Cleaning and inspection
Clean and inspect all parts.

Assembly
1. Assemble the springs on the cylinder with the
help of a 4 mm allen key. (tool 502 50 87-01)
Note! Springs with a greater resistance are av-
ailable, but should only be used together with a
longer bar. See IPL for spare part number.
2. Assemble the following parts:
• Tank unit and handle. Fig 49

• Cylinder cover. See the Operator's Manual.

• Bar and chain. See the Operator's Manual.

English – 43
Repair instructions

7.19 Replacing the fuel filter

NOTE!
Do not use knurled pliers to disconnect or
reconnect the fuel hose. This could dam-
age the hose and lead to leakage or frac-
ture.

1
First remove the old fuel filter from the tank unit
using special tool 502 50 83-01.

2
Pull the fuel hose out of the tank and pull off the
filter.

3
Fit the new fuel filter and feed the fuel hose back
into position.

7.20 Replacing the fuel hose

The fuel hose is moulded and can only be removed
from outside of the fuel tank.
Use suitable pliers with a plain cutting face and
loosen the hose (B) (see figure 46) from the fuel
tank. Align the cut-out against the plastic pin when
assembling.

7.21 Replacing the air-purge

Dismantling
1. Dismantle the cylinder cover and the air filter.
2. Loosen the screws (A). (see figure 29)
3. Loosen the filter holder from the rubber moun-
tings (B). (see figure 29)
4. Loosen the suction hose (C) and return hose
from the fuel pump. (see figure 30)
Assembling
1. Fit the return hose on the fuel pump.
2. Assemble the filter holder in the rubber moun-
tings. (B) (see figure 41) Fig 50
3. Snap the purge into the filter holder. (see figure
50)
4. Secure the screws (A) (see figure 41)
5. Assemble the air filter and cylinder cover.

44 – English
 Repair instructions

7.22 Piston and cylinder – removal

1
The fuel tank does not need to be removed when
removing the cylinder.

Remove:
• cylinder cover
• carburettor (see “Carburettor – removal”)
• silencer
• spark plug

2
Undo the four cylinder bolts from the underside and
lift the cylinder off carefully. (see figure 51)

Fig 51

3
Cover the opening in the crankcase. (see figure 53)

4
Remove the circlips from the ends of the gudgeon
pin and press it out. Then lift off the piston. (see
figure 52 and 53)

5
Remove the bearing from the little end of the con-
necting rod. (see figure 53)

Fig 52

If replacing the cylinder:

Remove the intake manifold, see “Air intake sys-
tem – removal”.

Cleaning and inspection Fig 53

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
(see figure 54)
Fig 54

English – 45
Repair instructions

Check the following:

• The surface coating of the cylinder is not worn

through, especially in the upper part of the
cylinder.
• The cylinder is free from score marks and
areas of wear.
• The piston is free from score marks. Small
scratches can be polished out with fine emery
paper.
• The piston ring is freely moving in its groove.
(see figure 55)

Fig 55

• Measure piston ring wear. This should not

exceed 1 mm. (see figure 56) Use the piston to
push the piston ring for correct alignment.
• The needle roller bearing is undamaged.
• The intake manifold is undamaged.
• That the air hoses and impulse hose are unda-
maged.
• Pressure test the decompression valve.

Fig 56

46 – English
 Repair instructions

Faults and causes

Score marks on the piston (A) A B
1. Incorrect carburettor setting. Too high over-
speed.
2. Too low octane fuel.
3. Too low or incorrect oil in the fuel.

Carbon build-up (B)

1. Incorrect carburettor setting. Too low over-
speed. Fig 57

2. Too much or incorrect oil in the fuel.

Piston ring breakage

1. Excessive engine speed.
2. Piston ring worn out.
3. Oversized piston ring groove.
(see figure 57)

7.23 Piston and cylinder – refitting

1
Lubricate the little end bearing with two-stroke oil
and insert it in the connecting rod. (see figure 58)

2
Fit the piston with the arrow pointing towards the
exhaust port. Push the gudgeon pin in and fit the
circlips. NOTE! Use new wire fuses. (see figure
59) If replacing the cylinder, fit the decompression
valve, tightening to a torque of 12–14 Nm.

3
Fit the intake manifold on the cylinder, with insula-
ting plate (4 screws). Fig 58

4
Lubricate the piston ring and piston with two-stroke
oil.

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

6
Fit the cylinder bolts, tightening them in diagonal
Fig 59
pairs to a torque of 13–15 Nm.

NOTE!
It is very important that there are no leaks
in the inlet system, otherwise the engine
may seize.

English – 47
 Repair instructions

Inlet manifold
The intake system has two intakes.
1. The lower intake leads the fuel and air mixture
from the carburettor to the cylinder.
2. The upper intake leads air to the cylinder.
Assembling the intake system
1
Assemble the carburettor flange (D) and air flange
(C) on the intake bellows (A). Now assemble the
intake bellows and the partition (B) on the cylinder
using tool 502 50 87-01.
(see figure 60)

Fig 60
D

48 – English
 Repair instructions

7.24 Cylinder – pressure testing

1
Remove:
• cylinder cover
• carburettor
• spark plug

2
Attach both the pressure testing covers. (see figure
61)

3
Loosen the screws on the muffler and press the Fig 61
rubber sheet 502 54 11-02 between the muffler and
cylinder. Tighten the top two muffler screws.

4
Fit the pressure testing spark plug 503 84 40-02
and connect the pressure testing tool 531 03 06-23.
(see figure 63)

5
Pump the pressure up to 80 kPa (0.8 bar). Wait
30 seconds. The pressure should not be less than
60 kPa (0.6 bar). Remove the cover plates from
the silencer and carburettor, tighten the bolts to the
specified torque. Remove the pressure test nipple
503 84 40-02 and refit the spark plug.

WARNING!
After pressure testing the cylinder,
check that the inlet manifold is Fig 62
seated correctly, otherwise the saw
may be damaged.

Fig 63

English – 49
Repair instructions

7.25 Crankshaft complete - dismantling

1
Remove the following:
• chain and bar
• clutch cover
• cylinder cover
• starter assembly*
• centrifugal clutch*
• carburettor*
• silencer*
• handle system
• hand guard
• piston and cylinder* Fig 64

* See special instructions.

2
Lift the crankshaft completely out of the crankcase.
(see figure 64)

7.26 Crankshaft bearings – replacement

Remove:
• The crankshaft complete from the crankcase.
1
Pull the crankshaft bearing off of the crankshaft
using a bearing puller. (see figure 65)

Fig 65

2
Place a new bearing on the shaft and push into
position using tool 502 50 30-18. (see figure 66).

Fig 66

50 – English
 Repair instructions

7.27 Crankshaft complete – reassembly

1
Fit the crankshaft complete in the crankcase.

Refit the following parts:

• piston and cylinder*
• handle system
• hand guard
• silencer*
• carburettor*
• centrifugal clutch*
• starter assembly*
• cylinder cover
• clutch cover
• chain and bar
* See special instructions.

7.28 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 plastic crankcase
Then screw in the thread insert using a suitable
bolt and spanner.
Fig 67

This type of thread insert is best suited for use

in plastic and magnesium, but not for repairing
threads in aluminium. In that case use a helicoil
insert with metric screw.
(see figure 67)

English – 51
Repair instructions

7.29 Replacing the bar bolt

Replacing the front bar guide.

1
Drain the oil tank.

2
Knock through the old guide bar bolt so that it falls
into the oil tank.
3
Remove the bolt from the oil tank.

4
Secure steel wire to the outer part of the bar bolt
(A), thread the steel wire through the oil tank and
out through the bolt hole in the crankcase. (see
figure 69)

5
Pull the steel wire so the bolt comes out of its hole.
(see figure 69)
Fig 68
6
Check that the bolt's square head fits in
the washer (D) which is positioned in the cut-out in
the crankcase.

7
Pull out the bar bolt with its nut. Place a spacer
between the nut and crankcase. (see figure 69)

8
Refill with chain oil.

Replacing the rear bar guide

1 Fig 69
Pull out the bar guide (C) with the help of slip-joint
pliers. (see figure 68)

2
Fit the bar guide with the help of a hammer.

52 – English
 Troubleshooting

8 Troubleshooting
Contents
8.1 Troubleshooting ...............................................................................................................54
8.2 Troubleshooting methods ................................................................................................55

English – 53
Troubleshooting

8.1 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

54 – English
 Troubleshooting

High rpm Acceleration och 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 8.2 Troubleshooting methods
Loose diaphragm rivet
Hole in diaphragm In addition to the faults described in the above
Leaking control diaphragm/cover table, trouble shooting can be carried out on
plate specific components or sub-systems of the
chainsaw. The various procedures are described
Will not “four- Blocked fuel tank vent in the relevant chapters, see the contents page, as
stroke” Blocked fuel filter follows:
Fuel line blocked
Loose or damaged fuel hose • Checking the operation of the chain brake
Impulse channel leaking
• Measuring the resistance of the stop plate
Impulse channel blocked
Loose cover on carburettor pump • Pressure testing the carburettor
side
• Pressure testing the decompression valve
Faulty pump diaphragm
Leaking air intake hose (rubber) • Pressure testing the cylinder
Loose carburettor mounting bolts
Needle valve set too low
Leak in metering system (air or fuel)
Metering unit incorrectly assembled
Loose diaphragm rivet
Hole in diaphragm
Leaking control diaphragm/cover
plate

English – 55
115 03 42-26
2007W16