Husqvarna 335XPT California, Workshop Manual

Page 1: ...101 89 44 26 335XPT Workshop Manual Eng Front 97 12 03 16 26 1 ...

Page 2: ...mbols 5 Technical data 6 Tools 8 Trouble shooting 10 Service data 12 Safety equipment 14 Starter 19 Ignition system 21 Centrifugal clutch 23 Carburettor 25 Tank unit 33 AV System 37 Crankshaft Piston and Cylinder 38 Bar bolt 42 Oil pump 43 Eng 02 09 97 12 03 16 26 2 ...

Page 3: ...g signs are displayed in the workshop manual and on the chain saw See page 5 If any of the warning symbols on the chain saw have be damaged or are missing a new symbol should be fitted as soon as possible so that the greatest level of safety is attained when the chain saw is used Reparation of a particular system When a particular system on the chain saw must be repaired proceed as follows 1 Look ...

Page 4: ...nal injury if the spring tension is activated on the cord pulley when removed Check that the brake is in the braking position when the pressure springs on the chain brake shall be removed Other wise the pressure spring can fly out and cause personal injury 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...

Page 5: ...een the guide bar tip and any object Contact with the guide bar tip can cause the saw to be thrown violently upwards and backwards kickback which can result in serious injury Switch off the engine by moving the stop switch to the STOP position before carrying out any checks or maintenance Operating position Choke Always wear approved protective gloves Regular cleaning is required Visual check Prot...

Page 6: ...FHP CD 0 3 0 01 Walbro WT Bar length Chain speed at Chain pitch Drive link gauge max power cm inches m s inches mm inches 29 39 12 16 18 3 3 8 1 3 0 050 Displacement Bore Stroke Max power speed cm3 cubic inches Ø mm Ø inches mm inches kW hp rpm 35 2 2 1 38 1 5 31 1 22 1 6 2 1 9600 Eng 02 09 97 12 03 16 26 6 ...

Page 7: ...res US pint cm3 min Litres US pint 0 3 0 63 3 7 0 16 0 34 Yes Weight without bar and chain Weight with bar and chain Handle heater kg lbs kg lbs Watt rpm 3 4 7 5 4 0 8 8 Idling speed Engagement speed Max speed Spark plug rpm rpm rpm 2 800 4 100 13 800 Champion NGK BPMR 7A Eng 02 09 97 12 03 16 27 7 ...

Page 8: ...8 English TOOLS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Eng 02 09 97 12 03 16 27 8 ...

Page 9: ... module 502 71 13 01 9 Feeler gauges air gap Ignition module adjustment 502 51 34 02 10 Assembly mandrel Assembly of spark plug guard 502 50 06 01 11 Hook for fuel filter Remove the fuel filter 502 50 83 01 12 Assembly fixture Fixture of the chain saw 502 51 02 01 13 Sleeve Dismantling the flywheel 502 51 94 01 14 Allen key 3 mm For M 4 screws 502 50 19 01 14 Allen key 4 mm For M 5 screws 502 50 1...

Page 10: ... manifold rubber Loose carburettor mounting bolts Worn throttle valve shaft Loose throttle valve screw Worn throttle valve Control system sticking Leak in throttle system air or fuel Control diaphragm centre knob is worn Hole in diaphragm Leaking control diaphragm cover plate Crankcase leaking Fuel line blocked Control system set too high Control system sticking Control system air or fuel Leaking ...

Page 11: ... control diaphragm cover Control system sticking Blocked muffler Adjust H screw Blocked fuel tank ventilator Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Control system sticking Leak in throttle system air or fuel Control system incorrectly assembled Loose diaphragm Hole in diaphragm Leaking contro...

Page 12: ...components that are bolted refer to the tightening torque in Nm Lubricate using two stroke oil Lubricate using engine oil Lubricate using grease Glued using 2 component adhesive Sealed using silicone 8 10 8 10 2 3 20 26 15 Eng 10 18 97 12 03 16 27 12 ...

Page 13: ...English 13 1 2 2 5 4 2 3 8 10 10 15 2 3 2 3 2 5 4 20 26 2 3 6 7 2 5 4 SERVICE DATA Eng 10 18 97 12 03 16 27 13 ...

Page 14: ...e the cover Chain brake Dismantling 1 Check that the chain brake is in the off position and dismantle the clutch cover and bolt A 6 Knock out the pin E and remove the knee link with the attached brake band 7 Unscrew the brake band from the knee link 5 Lift out the pressure spring by loosening the back edge using a screwdriver WARNING Check that the brake is in the on position Otherwise the pressur...

Page 15: ... E D D D D 5 Fit the cover and tighten the four bolts D 6 Move the brake to the off position and fit the clutch cover on the chain saw Adjust the chain tension see the Operator s manual Tighten the nut to 15 Nm 4 Put the brake in the on position and fit the spring Press it down by using a screwdriver on the back edge 3 Fit the kickback guard insert the two pins and fit the circlips B and C Eng 10 ...

Page 16: ... surface on the cylinder is positioned horizontally 2 Place gasket D in position on the cylinder 3 Carefully slide in the muffler without dislodging the gasket 4 Press the muffler down onto the cylinder when the holes in the muffler gasket and cylinder are aligned The gasket can be adjusted using a small screwdriver 5 Tighten the muffler s bolts to 8 10 Nm 6 Fit the muffler guard A A D C B B B D K...

Page 17: ...el L on the choke lever stop button is not worn 3 Check that the groove M and spring N on the lock plate are OK I H J E M K L K N B C D A E F G 6 Disconnect the electrical connection on the lock plate E and choke lever stop button J 3 Disconnect the choke rod G from the carburettor using a screwdriver and dismantle the choke lever stop button 4 Use a pair of thin nosed pliers and dismantle the loc...

Page 18: ...to 15 Nm 8 Check the stop function by starting the chain saw and make sure the saw stops when the stop button is moved to the stop position See the Operator s manual 5 Fit the pin from the right hand side C The press down the throttle lock A Check that the lock s locking arm goes down into the cut out in the throttle and fit the pin B 3 Using thin nosed pliers fit the lock plate E Secure using scr...

Page 19: ...that hold the starter A and cooling air guide B in position A B 4 Carefully lift up the spring housing so that the spring does not fly out and cause personal injury 5 If the starter cord is to be replaced cut it off and pull out the ends using a pair of thin nosed pliers from the handle and starter pulley 2 Pull out the handle 20 30 cm 8 12 and lift up the cord from the cut out in the starter pull...

Page 20: ... pulley 4 Fit the starter pulley against the recoil spring so that the end of the recoil spring hooks in the starter pulley Fit the bolt in the centre of the starter pulley 5 Pull out the starter cord through its hole in the cover and fit the handle secure with a double knot 7 Fit the starter on the chain saw Pull the starter handle slightly until you feel the starter dogs grip Now fit the four bo...

Page 21: ...mm 0 12 6 Fit the sleeve 502 51 94 01 on the shaft Do not screw it on too far a gap of 2 3 mm 0 08 0 12 must remain 7 Grip the flywheel and lift the saw Hit the sleeve with a hammer until the flywheel becomes loose 3 Loosen the cable D from the ignition module Unscrew the two M4 bolts E and lift out the ignition module F 4 If the ignition module shall be replaced pull up the contact spring from sp...

Page 22: ...arter A Assembly 1 Fit the starter pawls G 2 Fit the flywheel on crankshaft Rotate lightly so that the flywheel s key aligns with keyway on the crankshaft 3 Fit counterbalance washer I in the groove located on flywheel Use a 13 mm spanner and tighten the nut H to 20 26 N 4 Remove the piston stop fit the spark plug and rotate the flywheel so that its magnet is beside one of the ignition module s bo...

Page 23: ...nd their bearings in the shoe holder 3 When a spring breaks both springs must be replaced 4 A complete clutch or springs are available as spare parts 5 Wear on the chain sprocket 6 That the needle bearing is OK and that the bearing surface on the crankshaft is not damaged 7 That the clutch drum friction surface is OK and that the bearing surface is not damaged A B C D 5 If necessary dismantle the ...

Page 24: ...e holder can be pushed down between the clutch shoes A B C D 3 Use a 19 mm spanner and fit the clutch hub NOTE left hand thread 4 Remove the piston stop A and fit the spark plug Tighten ing torque 15 Nm 5 Fit the clutch cover Adjust the chain tension see the Operator s manual Tighten the bar cover nut to 15 Nm 2 Lubricate and fit the needle bearing D clutch drum C and washer B Eng 19 24 97 12 03 1...

Page 25: ...ring unit A contains the jets and fuel control func tions It is here the correct amount of fuel for the given engine speed and power is metered A B C Pump unit In the pump unit C fuel is pumped from the fuel tank to the metering unit One side of the pump diaphragm is connected to the crankcase and pulses in time with the pressure changes in the crankcase The other side of the diaphragm pumps the f...

Page 26: ...open Full throttle mode In the full throttle mode both valves are open and fuel is supplied through all three diffuser jets E F and G Part throttle mode In the part throttle mode the throttle valve H is partially open Fuel is supplied through the diffuser jets F and G Idling mode In the idling mode H the throttle valve is closed Air is sucked in through an aperture in the throttle valve and a smal...

Page 27: ...urettor fully Continue dismantling from point 7 on the next page 3 Dismantle the air filter S the two bolts and the air filter holder U 1 Dismantle the chain and bar See the Operator s manual 2 Dismantle the carburettor cover R CARBURETTOR Dismantling WARNING The fuel used in the chain saw poses the following hazards The fluid and its vapours are poisonous Can cause skin irritation Is highly infla...

Page 28: ...m surface B Drive the jet into the venturi using a hammer and punch 7 Remove the cover A over the metering unit and carefully remove the control diaphragm B with the gasket C 8 Undo the screw D and take out the needle valve P with lever arm E shaft and spring F 9 Remove the cover J over the pump unit and carefully remove the packing K and the pump diaphragm M 10 Using a needle or the like carefull...

Page 29: ...n 4 That the fuel screen is undamaged 5 That the tips of the high and low speed needles H and L are not damaged 6 That the air intake manifold is not cracked P H E L CARBURETTOR Assembly Maintain a high level of cleanliness when reassembling the carburettor Even small particles of dirt can cause operating problems Please refer to the exploded diagram on page 28 for the letters within brackets that...

Page 30: ...lever arm E is level with the heels next to the lever arm The lever arm can be bent if necessary 10 Fit the control diaphragm B with packing and cover A on the metering unit 11 Carry out a pressure test Pressure testing Pressure testing should be carried out with the carburettor fully assembled Testing should always be carried out after the carburettor has been repaired but a test can also be made...

Page 31: ... completed Fit a bar and chain combination approved for this model See Technical data in the Operator s manual The chain should not be adjusted too much approx 0 2 inches 5 mm should remain to the underside of the bar Fit a new air filter Carried out when the chain saw is assembled 1 Start the engine and adjust the idling speed using the T screw until the chain stops 2 Adjust the H needle until th...

Page 32: ...s set too lean If smoke comes from the muffler while the saw is 4 stroking it is set too rich Turn the H needle clockwise to achieve a setting which sounds right NOTE For optimal adjustment contact a qualified service agent with access to a tachometer Correctly adjusted carburettor A correctly adjusted carburettor means that the saw accelerates without hesitation and the saw four strokes a little ...

Page 33: ... all oil and fuel 2 Remove bolt A and the pulse tube B 3 Remove the bolts C and the exhaust guide plate D Cleaning and inspection Clean all parts and check that the fuel pipe and oil pipe are OK E A B 4 Press the manifold pipe into the hole on the tank unit at the same time as you push the engine unit towards the clutch side 5 Now loosen the oil pipe E D C C C WARNING The fuel used in the chain sa...

Page 34: ...t approx 35 mm 1 40 The pipe may need to be shifted in the rubber grommet Replacing the oil pipe and screen 1 Remove the screen and attached pipe using hook 502 50 83 01 2 Pull out the pipe through the oil tank 3 If necessary dismantle the screen and clean 4 Fit a new pipe from the outside through the hole in the oil tank Let the pipe protrude 40 mm 1 60 above the flat surface The total length of ...

Page 35: ... fastener place the unit in the hole in the tank from the outside Replacing the pulse tube 1 Pull out the old pulse tube using a pair of pliers 3 Pull in the ventilator with fitted vyon plug and pin using a pair of long nosed pliers from inside the tank 2 Insert a new pulse tube from the carburettor side and carefully pull it in from the engine side Eng 33 44 97 12 03 16 29 35 ...

Page 36: ...arburettor See page 31 8 Fit the muffler See page 16 9 Fit the centrifugal clutch See page 24 10 Fit the chain and bar See the Operator s manual After assembly has been completed refuel and test run the chain saw See the Operator s manual 3 Fit the chain catcher bolts C and guard D 2 Grip the manifold rubber using flat pliers through the hole in the tank unit and carefully pull it up A B Assembly ...

Page 37: ... s manual Anti Vibration System WARNING The fuel used in the chain saw poses the following hazards The fluid and its vapours are poisonous Can cause skin irritation Is highly inflammable Dismantling Dismantle the following parts 1 Chain and bar See the Operator s manual 2 Centrifugal clutch See page 23 3 Muffler See page 16 4 Carburettor See page 27 5 Starter See page 19 6 Ignition system and spar...

Page 38: ...the bearing C using the puller 504 90 90 01 NOTE Ensure that no dirt or other foreign particles fall into the dismantled components Continue to dismantle the piston and cylinder as follows 8 Dismantle the four bolts A 9 Dismantle the cylinder 10 Dismantle the crankshaft from the crankcase 11 Remove one of the piston s circlips press out the gudgeon pin and remove the piston 12 Remove the needle be...

Page 39: ...9 6 That the intake manifold is undamaged 7 That the needle bearing and its rubber seals are not damaged CRANKSHAFT PISTON AND CYLINDER Faults and causes Score marks on the piston 1 Incorrect carburettor setting Max speed too high 2 Too low octane fuel 3 Too little or incorrect oil in the fuel Carbon build up 1 Incorrect carburettor setting Max speed too low 2 Too much or incorrect oil in the fuel...

Page 40: ...on in the crankcase 7 Apply silicone rubber 504 98 26 01 to the contact surfaces of the crankcase halves 8 Press together the piston rings either by hand or by using the piston assembly set 502 50 70 01 Carefully slide on the cylinder 3 Oil the needle bearing and fit into the connecting rod little end 4 Fit the piston with the arrow facing towards the exhaust port Slide in the gudgeon pin and fit ...

Page 41: ... parts Flywheel See page 22 Starter See page 20 Carburettor See page 31 Muffler See page 16 Pressure testing The following parts must be dismantled when the crankcase and cylinder are pressure tested Carburettor See page 27 Muffler See page 16 Starter See page 19 Flywheel See page 21 Perform pressure testing as follows 1 Fit the cover plate 502 52 01 01 on the intake manifold Then connect tool 502...

Page 42: ...vice and knock out the bar bolt A using a hammer Assembly 1 Insert the new bar bolt A in its hole in the engine unit Make sure the bolt s square head fits in the square hole in the engine unit A 2 Pull the bolt in the right position by using the sleeve and nut Now assemble the following parts 3 Tank unit See page 36 4 Ignition system and spark plug See page 22 5 Starter See page 20 6 Carburettor S...

Page 43: ...antling the oil pump as follows 9 Unscrew the adjuster screw A and dismantle the pump piston B spring and washer 10 Dismantle the cover plate D Cleaning and inspection Clean all parts and check the following 1 That the oil pump drive s worm gear E is undamaged 2 That the taper on the adjuster screw A shows no signs of wear 3 That the guide C is undamaged 4 That the pump piston B is undamaged 5 Tha...

Page 44: ...e cover plate D Now assemble the following parts 4 Cylinder and crankshaft See page 40 5 Tank unit See page 36 6 Ignition system and spark plug See page 22 7 Starter See page 20 8 Carburettor See page 31 9 Muffler See page 16 10 Centrifugal clutch See page 24 11 Chain and bar See the Operator s manual 12 Test run the saw and check the oil flow See the Operator s manual D C A B Eng 33 44 97 12 03 1...