Workshop Manual: English

Workshop manual
435 435e 440e

English
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Contents
Workshop manual
Husqvarna 435, 435e och 440e
Contents
Index .......................................................................4
Introduction and safety instructions ................... 6
Technical data ......................................................10
Service tools ........................................................12
Service data ......................................................... 14
Safety equipment................................................. 16
Repair instructions ..............................................24
Carburettor ...........................................................33
Troubleshooting................................................... 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 – 3

Index
Index
B Symbols in the Workshop Manual 9
Symbols on the saw 9
Bar bolt 52
Structure 7
Replacing the bar bolt 52
Target group 7
C Tools 7
Carburettor 33 O
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
Dismantling the oil pump and screen 31
Design 33
Dismantling 35 P
Function 34
Piston and cylinder 45
Pressure testing the carburettor 39
Centrifugal clutch 30 Cylinder - pressure testing 49
Centrifugal clutch - refitting 31 Faults and causes 47
Centrifugal clutch - removal 30 Piston and cylinder - refitting 47
Inspection and cleaning 30 Piston and cylinder - removal 45
Chain brake 17
Chaine brake - reassembly 18 S
Cleaning and inspection 17 Service data 14
Dismantling the chaine brake 17 Special tools 12
Chain catcher 20 Silencer 19
Chain catcher - replacement 20 Cleaning and inspection 19
Crankcase and crankshaft 50 Silencer - refitting 19
Crankshaft bearings - replacement 50 Silencer - removal 19
Crankshaft complete - dismantling 50 Starter 25, 26
Crankshaft complete - reassembly 51 Changing a broken or worn starter cord 26
Cleaning and inspection 25, 26
F Replacing a worn recoil spring 27
Fuel system 44 Starter assembly - refitting 27
Replacing the fuel filter 44 Starter assembly - removal 25
Replacing the fuel hose/return hose 44 Tensioning the recoil spring 26
Replacing the air-purge 44
Start/Stop switch 20
Venting the fuel tank 42
Assembling the start/stop control 21
I Cleaning and inspection 20
Dismantling the start/stop control 20
Ignition module and flywheel 28
Cleaning and inspection 28 Stopping function 21
Ignition module - testing 27 Stop switch - resistance measurement 21
Ignition module and flywheel - refitting 29
T
Ignition module and flywheel - removal 28
Tank unit 42
Intake system 32
Assembly 43
Air intake system removal 32
Dismantling 42
Assembling the intake system 32, 48
Cleaning and inspection 32 Technical Data 10
Introduction and safety instructions 7 Threads 51
Changes 7 Repairing damaged threads 51
General 7 Throttle lock, throttle trigger
General Instructions 8 and return spring 22
Numbering 7 Cleaning and inspection 23
Safety 7 Throttle lock, throttle trigger and
Special Instructions 8 return spring - refitting 23
Throttle lock, throttle trigger and
return spring - removal 22
4 – English

Index
Trouble shooting 54
Trouble-shooting methods 55
V
Vibration damping system 43
Assembly 43
Dismantling 43
English – 5

Introduction and safety instructions
2 Introduction and safety instructions

Contents
2.1 General . ..........................................................................................................................7
2.2 Safety ..............................................................................................................................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
6 – English

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 – 7

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.
8 – English

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
Filling with chain oil
English – 9

Technical data
3 Technical data
Displacement Cylinder bore Stroke Max power/speed

cm3/cubic inches Ø mm/Ø inches mm/inches kW/hp/rpm
435/e: 37,0 / 2,25 39 / 1,53 31 / 1,22 1,6 / 2,1 / 9 000

440e: 40,9 / 2,49 41 / 1,51 31 / 1,22 1,8 / 2,4 / 9 000
Spark plug gap Ignition system Air gap Carburettor type

mm/inches mm/inches
435/e: 0,5 / 0,02 Walbro MBU-33 0,3 / 0,012 Zama EL41AC1T

440e: 0,5 / 0,02 Walbro MBU-33 0,3 / 0,012 Zama EL41AC1T
Effective cutting length Chain speed at Chain pitch Drive link

cm/inches max power – revs mm/inches mm/inches
m/s - r/min
435/e: 33-46 / 13-18 17,3 / 9 000 8,25 / 0,325 1,3 / 0,050 - 1,5 / 0,058
440e: 33-46 / 13-18 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
435/e: 2 900 3 800 NGK BPMR 7A

Champion RCJ 7Y
440e: 2 900 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
435/e: 0,37 / 0,78 9 0,25 / 0,53 Yes

440e: 0,37 / 0,78 9 0,25 / 0,53 Yes
Weight without Weight with

bar and chain bar and chain
kg / lbs kg / lbs
435/e: 4,4 / 9,7 6,2 / 13,7

440e: 4,4 / 9,7 6,2 / 13,7
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 504 91 06-05
3 Fuel filter hook Withdrawing the fuel filter 502 50 83-01
4 Allen key, 4mm For M5 bolts 502 50 87-01
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 504 63 93-01
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 30-22
16b Shaft extension Flywheel side 502 50 30-22
16c Shaft extension Cluch side 502 50 30-22
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
14 – English

Service data
9Nm 4mm
5Nm 4mm
23Nm 13mm
7Nm 4mm
5Nm 4mm
2.5Nm 4mm
8Nm 4mm
5Nm 4mm
2.5Nm 4mm
5Nm 4mm
5Nm 4mm
4Nm
5Nm 4mm
5Nm 4mm
English – 15

Safety equipment
6 Safety equipment
Contents
6.1 Dismantling the chain brake ............................................................................................17
6.2 Chain brake - reassembly ...............................................................................................18
6.3 Silencer - removal ...........................................................................................................19
6.4 Silencer - refitting ............................................................................................................19
6.5 Chain catcher - replacement ...........................................................................................20
6.6 Dismantling the start/stop control ....................................................................................20
6.7 Stop switch - resistance measurement ...........................................................................21
6.8 Assembling the start/stop control ....................................................................................21
6.9 Throttle lock, throttle trigger and return spring - removal ................................................22
6.10 Throttle lock, throttle trigger and return spring - refitting .................................................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 nut 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 min 0,6 mm
defects. Always use original spare parts.
• 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
cooling plate.
2
If the saw is fitted with a spark arrestor mesh (A) this Fig 11
must also be removed. If ��
necessary, use the com-
bination spanner to push down the plate edge and
remove the spark arrestor mesh (see figure 11).

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. When fitting the mesh,
make sure that the mesh is inserted in the right
position. If necessary, use the combination spanner
to insert the mesh.
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 start/stop control
1
Remove the cylinder cover and air filter.
2
Loosen the screw and dismantle the control (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 Fig 13

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.
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 multime-

ter to the ignition coil. NOTE! The switch must be
in the “on” (A) position to give the correct reading
(see figure 14).
The resistance must not be higher than 0.5 Ohm

when the switch is in the on position.
The stop switch is in the on position when the Fig 14

button is held down (A) (see figure 14) and in the
off-position the button is neutral (B) (see figure 15).
Fig 15
6.8 Assembling the start/stop control

1
Fit a new control and tighten the screw.
2
Fit air filter and cylinder cover.
Fig 16
English – 21

Safety equipment
6.9 Throttle lock, throttle trigger and

return spring – removal
1
Loosen the throttle actuator rod on the carburettor,
the fuel hose and the suction hose to the fuel pump.
2
Dismantle the tank unit from the engine unit by
loosening the screws A (see figure 17)
Fig 17
3
Dismantle the handle insert (B) by loosening the
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).
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 the throttle control (see figure 20).
Fig 20
7
Now loosen the spring.
Fig 21
22 – English

Safety equipment

• 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.
• 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.
2
Fit the throttle control (B) and spring (C) (see
figure 22).
3
Hold the spring and insert the throttle lock into the
cut-out in the handle (see figure 23).
4 Fig 22
Fit the throttle control pin (E) with the help of a
punch. (see figure 23)
5
Fit the throttle lock (D) by pressing it onto the shaft
in the handle (see figure 24).
6
Assemble the handle insert using a screw, when
the throttle control, lever, throttle cable and throttle
control lock with pin are fitted correctly (see figure
25).
Fig 23
Fig 24
English – 23

Repair instructions
7 Repair instructions
Contents
7.1 Starter assembly - removal .............................................................................................25
7.2 Changing a broken or worn starter cord ..........................................................................26
7.3 Tensioning the recoil spring .............................................................................................26
7.4 Replacing a worn recoil spring ........................................................................................27
7.5 Starter assembly - refitting ..............................................................................................27
7.6 Ignition module - testing ..................................................................................................27
7.7 Ignition module and flywheel - removal ...........................................................................28
7.8 Ignition module and flywheel - refitting ............................................................................29
7.9 Centrifugal clutch - removal . ...........................................................................................30
7.10 Centrifugal clutch - refitting . ............................................................................................31
7.11 Dismantling the oil pump and screen ..............................................................................31
7.12 Assembling the oil pump and screen . .............................................................................32
7.13 Air intake system - removal .............................................................................................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 Replacing the fuel hose/return hose . ..............................................................................44
7.21 Replacing the air-purge....................................................................................................44
7.22 Piston and cylinder - removal ..........................................................................................45
7.23 Piston and cylinder - refitting ...........................................................................................47
7.24 Cylinder - pressure testing ..............................................................................................49
7.25 Crankshaft complete - dismantling ..................................................................................50
7.26 Crankshaft bearings - replacement .................................................................................50
7.27 Crankshaft complete - reassembly ..................................................................................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)

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.

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

– removal
1
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
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).
3
Loosen the flywheel nut (E) using a suitable socket
and remove it (see figure 10).
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).

• Clean all parts, especially the tapers on the
flywheel and shaft.
• 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:
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
torque 4.5–6 Nm. Fit the blue cable on the ignition
module (see figure 12).
3 Fig 12
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. Care-
fully release the clutch springs (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.
• Check the thickness of the clutch shoes by
using vernier callipers to measure the diameter
of the clutch. If the diameter is less than 60
mm the clutch assembly must be replaced (see
figure 16).
Fig 16
30 – English

Repair instructions
7.10 Centrifugal clutch – refitting

1
Insert the clutch springs in the shoes.
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
it to a torque of 20 Nm, then connect the HT lead.
Then refit:
• cylinder cover
• guide bar
• 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
socket wrench or combination spanner.
Fig 18
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
Unbolt the oil pump from the crankcase and
remove it together with the oil pressure hose (see
E
figure 19).
Fig 19
5
The oil pump (E) is not adjustable (see figure 20).
E
• 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 Fit the intake manifold (A) and the partition walls
1–1.5 Nm. (B and C) on the cylinder using tool 502 50 87-01
(see figure 21).
Fit the drive gear, needle bearing, clutch drum and
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)
• plastic partition wall (B)
• rubber partition wall (C)
(see figure 21)
1
Now loosen the screws using tool 502 50 87-01..
Fig 21
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
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
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).
Fig 24
English – 33

Repair instructions
Function
The carburettor operates differently in the following
modes:
• Cold start mode

• Idling mode
• Part throttle mode
• Full throttle mode
In the cold start mode (see figure) the choke valve

(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.
Air is sucked in through an aperture in the throttle

valve and a small amount of fuel is supplied th-
rough the diffuser jet (D) (see figure 26).
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).
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).
Fig 28
34 – English

Repair instructions
Dismantling the carburettor

1. Dismantle the cylinder cover and the air filter.
2. Disassemble the handle holder (see figure 29).
Fig 29
3. ��
Push the throttle actuator rod out of the han-
dle part. Unhook it from the carburettor (see
figure 30).
Fig 30
4. Remove the return hose (B) and suction hose

(C). Loosen the fuel pump (D). Let the fuel
hose (G) remain in place (see figure 31).
NOTE!
Take care when lifting out the carburettor so
that the fuel hose does not become loose.
Fig 31
5. Loosen the screws (E) and unhook the rubber

mountings (F) (see figure 32).
Fig 32
English – 35

Repair instructions
6. Disassemble the pump cover (G) over the

measuring chamber cover (R) and carefully
remove the control diaphragm (H) with gasket
(J).
7. Unscrew the screw (K) and remove the needle

valve (L) with lever (M), shaft (N) and spring
(P).
8. Unscrew the screw (Q) above the pump unit

and carefully remove the gasket (S) and dia-
phragm (T).
9. Use a needle or similar device and carefully

pull up the fuel screen (U).
10. Unscrew the high (V) and low jet screws (W)
(see figure 34).
11. If necessary, dismount the throttle valve (X),

choke valve (Z) and air shutter (Y) and remove
the shafts with levers and springs (see
figure 34).
Fig 33
36 – English

Repair instructions
Cleaning and inspection 5. That the tips of the high (V) and low jet screws
Clean all units in clean petrol. (W) are not damaged (see figure 34).
6. That the intake manifold (R2) is undamaged
Use compressed air to dry the petrol on the com-
(see figure 33).
ponents. Direct the air through all channels in the
carburettor housing and ensure that they are not 7. The carburettor has an extra air shutter con-
blocked. Check the following: nected in parallel with the ordinary throttle
valve.
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 (L) and its lever (M) are
not worn (see figure 33).
4. That the fuel screen (U) is whole and clean
(see figure 33).
Fig 34
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.
Lubricate the shaft bearings with light oil.
2. Fit the high (V) and low (W) speed needles and
springs. Note! Do not fully tighten the screws.
This will damage the seats and needle tips.
3. Fit the fuel filter (U) by using the handle of a
small screwdriver. (see figure 33)
4. Fit pump cover (G), gasket (S) and measuring
chamber cover (R) over the pump unit (see
Fig 35
figure 33).
5. Fit the needle valve (L) with lever (M), shaft (N)
and spring (P) and tighten the screw (K). Fit
the expansion washer (F) (see figure 35).
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 36).
Fig 36
7. Fit the control diaphragm (T) with gasket (S)

and measuring chamber cover (R) over the
metering unit (see figure 37).
8. Press in the screen (U). Fit the measuring
chamber cover (R) and tighten the screw (Q)
(see figure 37).
9. Put together the gasket (J) and control dia-
phragm (H) and press up (see figure 37).
10. Assemble all the parts and tighten the four
screws (see figure 37).
11.. Carry out a pressure test.
Fig 37
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 38
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.
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
English – 39

Repair instructions
Assemble on the saw

1. Press the carburettor down towards the parti-
tion wall. Make sure that it gets into the correct
position.
2. Fit the filter holder by hooking the choke con-
trol into the choke lever (A).
3. Hook on the rubber mountings. Insert and
tighten the screws.
Fig 39
4. Insert the return hose (B) into its position in the

filter holder.
5. Press on the fuel diaphragm (D). Fit the suc-
tion hose (C) and return hose (B).
Fig 40
6. Hook in the throttle actuator rod into the carbu-

rettor. Thread the handle holder into the throttle
actuator rod (A). Push the rod forwards so that
it can be inserted into the handle part.
7. Push down the handle holder into the filter
holder (see figure 42).
Fig 41
8. Assemble the air filter and cylinder cover.

9. Mount the handle holder.
Fig 42
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 43
Operator's Manual).
435/e 16"
440e 16"
• The chain should not be tensioned more than
that it remains ~ 0,2 inches to the bar.
(See figure 43)
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.
435/e A=2
440e 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.
435/e B = 12500 -13 000, speed limitation
440e B = 12500-13 000, speed limitation
Use screwdriver 530 03 55-60.
4. Let the engine run at ”B” rpm ~ 1 minute, until Fig 44

warm.
Replacement of the L-needle
1. Screw the new L-needle to the bottom and
then turn it counterclockwise ”D” turns.
435/e D = 2,5
440e D = 2,5
(See figure 44)
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 actuator rod (G) from the
carburettor (see figure 45).
Fig 45
4. Dismantle the fuel hose (B) and the fuel pump
return hose (D) (see figure 45).
5. Remove the screws. (A). Loosen the handle
(see figure 46).
6. Dismantle the fuel tank.
NOTE!
Exercise care so that the fuel hose and
throttle cable are not damaged.
7.17 Venting the fuel tank

The two-way valve (C) has the following properties
(see figure 47):
• 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.
• 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
Fig 46
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. 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)
3. Switch the pump to pressure mode. Fig 47
4. After pumping the indicator should stop at max.

7 kPa.
42 – English

Repair instructions
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
insert the fuel hose (in J), return hose (in H) in
the bottom of the carburettor compartment (see
figure 48).
3. Fit the handle with the screws (A). Tighten the
screws with the torque set out in the service
data (see figure 46). Fig 48
4. Fit the fuel hose (B) and fuel pump return hose
(D) on the carburettor (see figure 45).
5 Mount the throttle actuator rod (see figure 45).
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 49
help of a 5 mm allen key (see figure 49).
3. Dismantle the springs on the tank unit with the
help of a 5 mm allen key (tool 502 50 18-01)
(see figure 50).
Clean and inspect all parts.
Assembly
1. Assemble the springs on the cylinder with the
help of a 5 mm allen key (tool 502 50 18-01).
Note! Springs with a greater resistance are av-
ailable, but should only be used together with
a longer bar. See illustrated part list for spare
part number.
Fig 50
2. Assemble the following parts:
• Tank unit and handle.
• 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 (B) out of the tank unit and pull
off the filter.
3
Fit the new fuel filter (A) and feed the fuel hose
back into position.
7.20 Replacing the fuel hose/

return hose
The fuel hose is moulded and can only be removed
Fig 51
from outside of the fuel tank.
Use suitable pliers with a plain cutting face and
loosen the hose (B) (see figure 45) from the fuel
tank. Align the cut-out against the plastic pin when
assembling. Replace the return hose when required.
7.21 Replacing the air-purge

Dismantling
1. Dismantle the cylinder cover and the air filter.
2. Loosen the suction hose (C) and return hose
from the fuel pump (see figure 31).
3. Unsnap the fuel pump from the filter holder.
Assembling
1. Fit the return hose on the fuel pump.
2. Snap the purge into the filter holder (see figure
51).
4. Assemble the air filter and cylinder cover. Fig 52
44 – English

Repair instructions
7.22 Piston and cylinder – removal

1
Remove:
• cylinder cover
• carburettor (see “Carburettor – removal”)
• silencer
• spark plug
• fuel unit
2
Undo the four cylinder bolts from the underside and
lift the cylinder off carefully (see figure 52).
Fig 53
3
Cover the opening in the crankcase (see figure 54).
4
Remove the circlips from the ends of the gudgeon
pin and press it out. Then lift off the piston (see
figure 53 and 54).
5
Remove the little end bearing (see figure 54).
Fig 54
If replacing the cylinder:

Remove the intake manifold, see “Air intake sys-
tem – removal”. Fig 55

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 56)
Fig 56
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 57)
Fig 57
• Measure piston ring wear. This should not

exceed 1 mm (see figure 58). 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 58
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 59
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 59)
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 60).
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 60).
3
Fit the intake manifold on the cylinder, with insula-
ting plate (4 screws).
4 Fig 60
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
pairs to a torque of 13–15 Nm.
NOTE! Fig 61
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
Mount the intake manifold (A) and the partition
walls (B and C) on the cylinder using tools 502 50
87-01 (see figure 62).
Fig 62
48 – English

Repair instructions
7.24 Cylinder – pressure testing

1
Remove:
• cylinder cover
• carburettor
• spark plug
2
Mount cover plate 504 63 93-01 (see figure 63).
3
Fig 63
Loosen the screws on the muffler and press the
rubber sheet 502 54 11-02 between the muffler and
cylinder. Tighten the top two muffler screws (see
figure 64).
4
Fit the pressure testing spark plug 503 84 40-02
and connect the pressure testing tool 531 03 06-23
(see figure 64).
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. Fig 64
WARNING!
After pressure testing the cylinder,
check that the inlet manifold is
seated correctly, otherwise the saw
may be damaged.
Fig 65
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 66
* See special instructions.
2
Lift the crankshaft completely out of the crankcase
(see figure 66).
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 67).
Fig 67
2
Place a new bearing on the shaft and push into
position using tool 502 50 30-18 (see figure 68).
Fig 68
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 69
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 69).
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 Fig 70
out through the bolt hole in the crankcase (see
figure 70).
5
Pull the steel wire so the bolt comes out of its hole
(see figure 71).
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 71).
8
Fig 71
Refill with chain oil.
Replacing the rear bar guide

1
Pull out the bar guide (C) with the help of slip-joint
pliers (see figure 70).
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
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
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

504 64 38-26
2008W11

Workshop Manual: English

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Workshop manual

435 435e 440e

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2 Introduction and safety instructions

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2 Introduction and safety instructions

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2.8 General instructions 2.9 Special instructions

Poor chain lubrication can result in failure of the

Take care to ensure that the spring inside the

Before removing the tensioning spring from the

After completing the repair the chain brake must be

Always consider the fire risk. A chainsaw can

Inspect the chain catcher and replace it if it is

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2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual

Choke Lever This symbol warns of personal injury

Filling with chain oil

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Displacement Cylinder bore Stroke Max power/speed

435/e: 37,0 / 2,25 39 / 1,53 31 / 1,22 1,6 / 2,1 / 9 000

Spark plug gap Ignition system Air gap Carburettor type

435/e: 0,5 / 0,02 Walbro MBU-33 0,3 / 0,012 Zama EL41AC1T

Effective cutting length Chain speed at Chain pitch Drive link

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Idling speed Engagement speed Spark plug

435/e: 2 900 3 800 NGK BPMR 7A

435/e: 0,37 / 0,78 9 0,25 / 0,53 Yes

Weight without Weight with

435/e: 4,4 / 9,7 6,2 / 13,7

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Item Description Used for Order no.

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6.2 Chain brake – reassembly

Secure the circlip (A) (see figure 6).

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Guide bar length Height

• Hold the chainsaw over a firm surface. The

Cleaning and inspection

6.4 Silencer – refitting

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6.5 Chain catcher – replacement

Cleaning and inspection Fig 13

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6.7 Stop switch – resistance

Clean the mating surfaces and check the resis-

Measure the resistance by connecting a multime-

The resistance must not be higher than 0.5 Ohm

The stop switch is in the on position when the Fig 14

6.8 Assembling the start/stop control