Husqvarna 335XPT California Instruction manual

101 89 44-26
335XPT
Workshop Manual
Eng Front 97-12-03, 16.261

2– English
CONTENTS
Introduction ....................................................3
Safety instructions .........................................4
Key to symbols...............................................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, 16.262

English – 3
INTRODUCTION
Layout
This workshop manual can be used in two different ways:
• Reparation of a particular system on the chain saw.
• Dismantling and Assembling the entire chain saw.
General
This workshop manual describes in detail how trouble shooting,
repairs and testing of the chain saw should be carried out. The
different safety precautions that must be taken when carrying
out repairs are also described.
Dismantling and assembling the
entire chain saw
When the entire chain saw shall be stripped and rebuilt proceed
as follows:
1. Turn to page 19, which deals with the Starter and carry out
the instructions under the heading Dismantling.
2. Go forward in the manual and carry out Dismantling in the
order the sections appear.
3. Return to the Starter on page 19 and carry out the instruc-
tions under Cleaning and inspection.
4. Work forward in the manual and carry out Cleaning and
inspection in the order the sections appear.
5. Order or collect all requisite spare parts from the spare
parts store.
6. Turn to page 44 that deals with the Oil pump and carry out
the instructions under Assembly.
7. Work towards the beginning of the manual and carry out
Assembly in the order the sections appear.
To broaden understanding some sections are introduced by a
Description of the unit in question.
Safety
Note!
The section dealing with safety should be read and
understood by all persons repairing or servicing the
chain saw.
Warning 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 up the page for the system.
2. Carry out the sections:
• Dismantling
• Cleaning and inspection
• Assembly
Numbering
Positioning indicators to components within the figures are
denoted by A, B etc.
Positioning indicators start again from A in each new section.
Tools
Special tools must be used during certain procedures. All
service tools are listed in this workshop manual. Usage is
evident from respective sections.
Always use Husqvarna's original:
• Spare parts
• Service tools
• Accessories
Target group
The workshop manual has been written for persons assumed to
have a general knowledge of the repair and service to small
engines.
The workshop manual should be read and understood by those
persons who carry out repairs and service to the chain saw. The
manual is also suitable for use during the training of new
employees.
Modifications
Modifications to the chain saw will be successively introduced
during production. When these modifications affect servicing
and/or spare parts special service bulletins will be sent out on
each occasion. This means that this workshop manual in time
will be out-of-date. To prevent this the manual should be read
with all service bulletins regarding the chain saw in question.
Eng 02-09 97-12-03, 16.263

4– English
SAFETY INSTRUCTIONS
Special instructions
The fuel used in the chain saw has the following dangerous
characteristics:
• The liquid and its vapours are poisonous.
• Can cause skin irritation.
• Is extremely inflammable.
The bar, chain and clutch cover (chain brake) must be fitted
before the saw is started otherwise the clutch can come loose
and cause personal injury.
Use ear protection when test running.
Do not use the saw before it is adjusted so that the chain does
not rotate when idling.
Do not touch the muffler after test running until it has cooled.
Risk of burn injuries.
Inadequate chain lubrication can result in the chain breaking,
which can cause serious, even fatal injury.
Make sure the starter recoil spring does not fly out and cause
personal injury.
The spring can fly out and cause personal 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.
General instructions
Workshops where chain saws are to be repaired must be
equipped with safety equipment as set out in local directives.
No one may repair the chain saw without first reading and
understanding the contents of this workshop manual.
The boxes shown below can be found in appropriate places in
this workshop manual. Warning boxes are positioned before the
procedures they refer to.
WARNING!
Warning boxes warn for the risk of personal
injuries if the instructions are not followed.
NOTE!
This box warns of damage to material if the instructions
are not followed.
!
Eng 02-09 97-12-03, 16.264

English – 5
KEY TO SYMBOLS
Symbols
CAUTION! Chain saws can be dangerous!
Careless or incorrect use can result in
serious or fatal injury to the operator or
others.
Please read the instructions carefully and
make sure you understand them before
using the saw.
Always wear:
• Approved protective helmet
• Approved hearing protection
• Protective glasses or visor
Where possible, always use both hands
when operating the chain saw.
Avoid contact between 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.
Protective glasses or a visor must be worn.
Refuelling.
Chain oil and chain oil flow adjustment.
This saw should only be used by
persons who are specially trained
in tree maintenance work.
See the Operator's manual!
Eng 02-09 97-12-03, 16.265

6– English
TECHNICAL DATA
Spark plug gap Ignition system Air gap Carburettor
mm/inches mm/inches
0.7/0.028 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, 16.266

English – 7
TECHNICAL DATA
Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump
Litres/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, 16.277

8– English
TOOLS
12 34
56 7
8 9 10 11
12 13 14 15
Eng 02-09 97-12-03, 16.278

English – 9
TOOLS
Pos Description Used to Order no.
1 Piston assembly tool Assembling the piston 502 50 70-01
2 Cover plate, manifold Seal the manifold 502 52 01-01
3 Cover plate, exhaust Seal the exhaust port 502 52 31-01
4 Pressure tester Produce pressure for testing 502 50 38-01
5 Puller Removing bearing from crankshaft 504 90 90-01
6 Piston stop Lock the crankshaft 502 50 33-01
7 Tachometer Carburettor adjustment 502 71 14-01
8 Test spark plug Check the ignition 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 18-01
15 Allen key, 3 mm For M-4-screws 502 50 86-01
15 Allen key, 4 mm For M-5-screws 502 50 87-01
The tools listed here are service tools used for the chain saw in
question. In addition to these tools a standard set of tools is
also required.
Eng 02-09 97-12-03, 16.279

10– English
TROUBLE SHOOTING
Difficult starting
Carburettor leaking
fuel
Idling (low rpm) (cont.)
Trouble shooting schematic
Faults that can develop on the chain saw are divided into four
groups as follows. In each category, possible malfunctions are
shown on the left, with a list of possible faults on the right. The
most probable fault is given first and so on.
Adjust L-screw
Air filter blocked
Choke not working
Worn choke shaft
Worn choke valve
Fuel filter blocked
Fuel line blocked
Piston ring seized
Blocked impulse channel
Loose or faulty fuel pipe
Hole in diaphragm
Worn needle valve/needle
Control system sticking
Control system set too high
Leak in control system (air or fuel)
Loose cover on carburettor
pump side
Worn needle valve
Control system set too high
Control system sticking
Flooding when the
engine is not running
Starting
Idles when L-screw
is closed Worn needle valve/needle
Leaking control diaphragm/cover plate
Control system sticking
Worn throttle lever in control system
Faulty diffuser jets
Fuel filter blocked
Fuel line blocked
Leaking 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 control diaphragm/cover plate
Faulty diffuser jets
Crankcase leaking
Control system set too high
Control system sticking
Control system damaged
Worn needle valve
Leaking control diaphragm/cover plate
Control system incorrectly assembled
L-screw requires
constant adjustment
Idling uneven
Too much fuel when
idling
Adjust L-screw
Leaking manifold (rubber)
Loose carburettor mounting bolts
Loose or faulty fuel pipe
Fuel filter blocked
Fuel line blocked
Fuel tank ventilator blocked
Throttle lever shaft stiff
Throttle cable sticking
Defective throttle return spring
Bent throttle lever shaft stop
Faulty diffuser jets
Adjust L-screw
Worn needle valve/needle
Control system set too high
Worn throttle lever in control system
Leaking control diaphragm/cover plate
Control system sticking
Will not idle
Idling too rich
Idling (low rpm)
Eng 10-18 97-12-08, 17.3710

English – 11
TROUBLE SHOOTING
High rpm Acceleration and retardation
Adjust L-screw
Adjust H-screw
Blocked air filter
Blocked fuel tank ventilator
Blocked fuel filter
Fuel line blocked
Loose or damaged fuel line
Impulse channel blocked
Loose cover on carburettor pump side
Faulty pump diaphragm
Leaking manifold (rubber)
Loose carburettor mounting bolts
Control system set too low
Control system incorrectly assembled
Control system sticking
Faulty diffuser jets
Blocked muffler
Adjust L-screw
Adjust H-screw
Faulty pump diaphragm
Control system set too high
Control system sticking
Faulty diffuser jets
Adjust L-screw
Adjust H-screw
Blocked air filter
Faulty pump diaphragm
Faulty diffuser jets
Does not accelerateWill not run at full
throttle Adjust H-screw
Blocked air filter
Blocked fuel tank ventilator
Blocked fuel filter
Fuel line blocked
Loose or damaged fuel line
Impulse channel leaking
Impulse channel blocked
Loose cover on carburettor pump side
Faulty pump diaphragm
Leaking manifold (rubber)
Loose carburettor mounting bolts
Control system set too low
Control system damaged
Control system incorrectly assembled
Leaking 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 control diaphragm/cover
Blocked fuel tank ventilator
Blocked fuel filter
Fuel line blocked
Loose or damaged fuel line
Impulse channel leaking
Impulse channel blocked
Loose cover on carburettor pump side
Faulty pump diaphragm
Leaking manifold (rubber)
Loose carburettor mounting bolts
Control system set too low
Leak in throttle system (air or fuel)
Control system incorrectly assembled
Loose diaphragm
Hole in diaphragm
Leaking control diaphragm/cover plate
Low power
Will not "four-stroke"
Engine stalls when
throttle is released
Too rich acceleration
Trouble shooting methods
In addition to faults given in the above schematic, trouble
shooting can be carried out on a specific component or sub-
system of the chain saw. The different testing procedures are
described in respective sections and are as follows:
1. Pressure testing the carburettor.
See page 30.
2. Pressure testing the crankcase and cylinder.
See page 41.
Eng 10-18 97-12-08, 17.3711

12– English
SERVICE DATA
Character key
Numbers by 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, 16.2712

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, 16.2713

14– English
SAFETY EQUIPMENT
Inspection
Clean and inspect all parts.
The thickness of any part of the brake band must not be below
0.8 mm (0.031").
A
D
D
D
D
B
C
E
2. Remove the circlips (B) and (C) and press/knock out the
pins.
3. Remove the handle.
4. Remove the four bolts (D) and remove 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 pressure spring can fly out and
cause personal injury.
Eng 10-18 97-12-03, 16.2714

English – 15
SAFETY EQUIPMENT
Assembly
Assemble the chain brake as follows:
1. Screw together the brake band and knee link.
2. Grease the moving parts on the knee link and assemble the
unit in the cover and knock in pin (E).
B
C
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 10-18 97-12-03, 16.2715

16– English
SAFETY EQUIPMENT
Chain catcher
Remove the chain and bar. See Operator's manual.
Check the spike (J) and chain catcher (K). Replace if the parts
are damaged. Bolts shall be tightened to 6 Nm.
Fit the chain and bar. See Operator's manual.
Inspection
Clean all parts and check the following:
1. That the spark arrester (C) is OK.
2. That the muffler and muffler mountings are not cracked or
show signs of other defects.
3. That the gasket (D) is OK.
Assembly
1. Place the chain saw in the fixture (see service tools) or in a
vice so that the muffler's contact 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
J
Dismantling
Dismantle the muffler as follows:
1. Dismantle the muffler guard by unscrewing the two bolts
(A).
Muffler
!
2. Turn the saw and unscrew the three bolts (B) that hold the
muffler in position.
3. Lift out the muffler to the side.
4. Remove the gasket.
WARNING!
Do not touch the muffler until it has cooled.
Risk of burns.
Eng 10-18 97-12-03, 16.2716

English – 17
SAFETY EQUIPMENT
Throttle lock and stop function
Dismantling
Dismantle the throttle lock as follows:
1. Dismantle the clutch cover and carburettor cover.
2. Knock out the pins (B) and (C) from the left-hand side and
unscrew the bolt (D) and pull up the throttle lock (A).
Inspection
Clean all parts and check the following:
1. That the throttle lock's activation mechanism (K) is not
worn.
2. That the heel (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
JE
M K
LK
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 lock plate
(E).
5. Disconnect the throttle's bearing (F).
6. Lift out the throttle (H). When the throttle is halfway out
push away the throttle rod (I) from the fastening in the
throttle.
Eng 10-18 97-12-03, 16.2717

18– English
SAFETY EQUIPMENT
Assembly
Assemble the parts as follows:
1. Connect the electrical connection to the lock plate (E) and
choke lever/throttle (J).
I
H
JE
F
G
D
E
F
B
C
D
A
6. Hook on the throttle bearing (F). Use a screwdriver to fit the
choke rod (G) on the carburettor.
7. Fit the clutch cover and carburettor cover. Adjust the chain
tension, see the Operator's manual. Tighten the clutch
cover nut 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
screw (D).
4. Slide up the choke lever/start control (J).
2. Slide in the throttle (H). At the same time fit the throttle rod
(I) on the throttle. Do not hook it onto the bearing (F) yet.
Eng 10-18 97-12-03, 16.2718

English – 19
STARTER
!WARNING!
• The recoil spring is under tension when in its housing
in the starter and can, with careless handling, fly out
and cause personal injury.
• Care should be exercised when replacing the recoil
spring or starter cord. Wear protective glasses.
Dismantling
1. Unscrew the four bolts 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 pulley.
3. Unscrew the centre bolt and lift out the washer and starter
pulley.
Eng 19-24 97-12-03, 16.2719

20– English
STARTER
Cleaning and inspection
Clean the parts and check as follows:
1. Starter cord.
2. The dogs in the starter pulley.
3. That the pawls on the flywheel are OK, and spring back
towards the centre and move freely.
Assembly
1. Lubricate the new recoil spring using thin oil without taking
it out of its housing.
2. Carefully fit the spring housing in the starter housing so that
the spring does not fly out and cause personal injury.
3. Insert and attach the new starter cord in the starter pulley.
Wind on approx. 3 turns on the starter 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
bolts and tighten to 2.5-4 Nm.
6. Lift up the starter cord from one of the cut-outs in the starter
pulley and turn the starter pulley approx. 2 turns clockwise.
Check the cord tension:
A. Pull out the cord completely.
B. In this position it should be possible to turn the starter
pulley by hand a further 1/2 - 3/4 turn.
Eng 19-24 97-12-03, 16.2720