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SERVICE MANUAL JONSERED

JONSERED
Model Bore Stroke Displacement Drive
nun (in.) nun (in.) cc (cu. in.) Type
2036 Turbo 38 32 36.3 Direct
(1.5) (1.26) (2.2)
2040 Turbo 40 32 40.2 Direct
(1.57) (1.26) (2.5)

Saws identified as Turbo models use Ib adjust the mixture screws,firstre- indicate air leaks, plugged passages or
the centrifugal force of the cooling air move and clean the airfilter,then rein- other problems.
moved by the fan to separates some of stall it. Start the engine and allow it to Ib remove carburetor (3—Fig. J112),
the foreign matterfi-omair de livered to run until it reaches normal operating first remove cylinder cover and clean
the carburetor intake. Larger wood temperature. If necessary, turn each of the area around the carburetor. Re-
chips and other impurities in air circu- the mixture needles clockwise until move air filter (1) and filter holder (2).
lated by the cooling fan are thrown to seated lightly, then back the needles Disconnect fuel line, throttle cable and
the outside by centriftigal force, while out (counterclockwise) to the initial set- choke lever. Remove the carburetor.
cleaner air nearer the fan is collected by ting so the engine can be started. When installing carburetor, be sure
a nozzle and directed toward the carbu- that throttle cable is inserted through
retor intake. Finer impurities are cap- Turn the idle speed stop screw (T) so
the engine idles at about 3,000 rpm. Ad- guide in airfilterholder (2). Tighten the
tured by the air filter. carburetor attaching screws to the
just the low-speed mixture needle (L) so
the engine idles smoothly and acceler- torque listed in the TIGHTENING
MAINTENANCE ates without hesitation. Adjust the idle TORQUE paragraph.
SPARK PLUG. Recommended speed to just slower than clutch engage-
ment speed, then recheck low-speed IGNITION. All models are equipped
spark plug is Champion RCJTY or NGK with a breakerless electronic ignition
BPMR 7A. Electrode gap should be 0.5 mixture adjustment.
system. All electronic circuitry is con-
mm (0.020 in.). The spark plug should Adjust the high-speed mixture nee- tained in a one-piece ignition mod-
be tightened to the torque listed in the dle (H) to provide the best performance ule/coil (2—Fig. J113) located outside
TIGHTENING TORQUE paragraph. while operating at maximum speed im- the fiywheel. Ignition timing is fixed
der load. Maximum no-load speed (with and not adjustable. The fiywheel at-
CARBURETOR. Walbro WT 289 bar and chain installed) is 13,000 rpm. taching nut should be tightened to the
carburetor is used. Refer to the appro- The high-speed mixture screw may be torque listed in TIGHTENING
priate Walbro section of the set slightly rich to improve perform- TORQUE paragraph.
CARBURETOR SERVICE section for ance under load. The engine may be Air gap between the legs of the mod-
service and exploded views. damaged if the high-speed screw is set ule/coil and the flywheel magnets
Initial setting of the low-speed and too lean. should be 0.3 mm (0.012 in.). When in-
high-speed mixture needles is 1-1/4 Final adjustment of the mixture nee- stalling, set the air gap between the fiy-
turns openfi-omlightly seated. Refer to dles should be within 1/4 turn of the ini-
Fig. J i l l . wheel magnets and the legs of the
tial settings. Large differences may ignition module as follows.

1-1 1/4
1-1 1/4

6 I Fig. J112'-Explod0d vlaw of


angina Intake syatam.
1. Air cleaner
2. Filter base
3. Carburetor
4. Gasket
5. Filter bracket
6. Insulator
7. Intake manifold
8. Impulse tube
9. Air intake nozzle
10. Adjustment guide
Fig. J111—VI0W of carburetor mIxturB neodl0 lo-
cations. Low'Bpeed mixture needh Is located at
(L), high^paed mixture needla Is at (H) and Idle
apeed atop acrew la located tf (T).

niustrations couitesy Jonaered Power Products AB


315
JONSERED CHAIN SAW

cause the engine to be hard to start, run


rough, have low power and overheat.
Refer to ENGINE SERVICE section of
this manual for crankcase pressure test
procedure. If crankcase leakage is indi-
cated, pressurize the crankcase and use
a solution of soap and water to check
gasket, seals, pulse line and castings
for leakage.
16
TIGHTENING TORQUE. Recom-
mended tightening torque values are as
follows.
Carburetor 3-4 N-m
(26.5-35.4 in.-lb.)
Clutch hub 30-35 N-m
(265-310 in.-lb.)
Crankcase/Cylinder 10-12 N«m
(88.5-106 in.-lb.)
Flywheel 25-30 N-m
(221-265 in.-lb.)
Lower housing to engine. . . 10-12 N-m
(88.5-106 in.-lb.)
Muffler 7-8 N.m
(62-71 in.-lb.)
Spark plug 20-22 N-m
(177-195 in.-lb.)
Starter 2-3 N-m
(18-26.5 in.-lb.)
PISTON, PIN, RING AND CYLIN-
21 DER. Tb disassemble, remove cylinder
cover, air fllter, starter housing, fly-
wheel, muffler, saw chain, guide bar,
clutch assembly and oil pump. Remove
24 the screw that attaches handlebar to
Fig. J113—Exploded view of engine components typical of all models. cylinder. Unbolt and remove the carbu-
1. Cylinder 8. Crankshaft/connecting rod assy. 15. Oil pump housing 22. Oil tank cap retor, adapter housing and turbo noz-
2. Ignition module/coil 9. Crankcase lower half 16. Guard plate 23. Screw zle.
3. Piston ring 10. Screw 17. Rubber connector 24. Vent
4. Piston 11. Ball bearings 18. Pump cylinder 25. Fuel tank cap Remove the four screws (23—Fig.
12. Seals 19. Suction pipe 26. Flywheel
5. Piston pin
13. Worm gear 20. Filter screen 27. Spring
J113) attaching the engine crankcase to
6. Retaining ring
7. Needle bearing 14. Pump plunger 21. Engine/tank housing 28. Starter pawl the lower housing (21). Lift the engine
assembly from the lower housing. Re-
move the four screws (10) attaching
Install the ignition module, but engine oil, mix at a ratio of 25:1. Always lower crankcase half (9) to cylin-
tighten the two screws only enough to use a separate container to mix gaso- der/crankcase (1). Tap lower crankcase
hold it in place away from the flywheel. line and oil before filling the fuel tank. half with a plastic hammer to separate
Insert setting gauge (part No. 502 51 The manufacturer recommends not us- the crankcase halves. DO NOT use a
34-05) or brass/plastic shim stock ofthe ing fuel containing alcohol. screwdriver to pry the halves apart as
proper thickness between the legs of The saw is equipped with an auto- the crankcase sealing surfaces are eas-
the ignition module and the flywheel, matic chain oiling system. Oil is deliv- ily damaged.
then turn the flywheel until the fly- ered to the guide bar by the automatic Withdraw the piston, crankshaft and
wheel magnets are near the module chain oil pump. The manufacturer rec- connecting rod assembly from the cylin-
legs. Loosen the screws attaching the ommends using good quality oil de- der and upper crankcase half. Remove
ignition module and press legs ofthe ig- signed for lubricating saw chain. retaining rings (6) and push pin (5)
nition module against the setting Automotive engine oil may also be from the piston (4). Remove needle
gauge. Tighten the two attaching used. Select oil viscosity according to bearing (7) from the bore in connecting
screws securely. Remove the setting the ambient temperature. rod small end.
gauge, then turn the flywheel and Make sure the reservoir is fllled at all If necessary to disassemble the
check to be sure the flywheel does not times and the small oil passages do not crankshaft, main bearings and seals,
hit the legs of the coil. become blocked. The volume of oil deliv- refer to CRANKSHAFT AND
ered by the pump is not adjustable. CONNECTING ROD paragraph.
LUBRICATION. The engine is lu- Inspect the cylinder for any damage
bricated by mixing oil with the gasoline and install new parts as necessary. If
fuel. The manufacturer recommends REPAIRS the chrome plating is worn from the cyl-
mixing Jonsered two-stroke engine oil inder, a new cylinder should be in-
with regular grade gasoline at a ratio of CRANKCASE PRESSURE TEST. stalled. The piston, ring and cyhnder
50:1. When using regular two-stroke An improperly sealed crankcase can are available in standard size only. The

lllustralions courtesy Jonsered Power Products AB


316
SERVICE MANUAL JONSERED

piston and cylinder are available for crankshaft assemblies can align the in TIGHTENING TORQUE para-
service only as a matched set and the shaft. graph.
cylinder should not be bored oversize. Remove the crankshaft and connect-
Lubricate the needle beadnjf (7—Fig. ing rod assembly as described in OIL PUMP. The automatic oil pump
J113) with engine oil before assem- PISTON, PIN, RING AND CYLINDER is driven by worm gear (13—Fig. J113)
bling. Position the piston ovei' the con- paragraphs. The crankshaft should on the crankshaft. Oil is pumped by
necting rod and needle bearing: with the turn smoothly inside main bearings plunger (14) as it rotates in the pump
arrow on piston crown toward the ex- (11) with no perceptible play or ratchet- cylinder (18). Pump output is not ad-
haust side of engine. Install retaining ing. justable for these models.
rings (6) with the opening toward the Refer to the OIL PUMP paragraph To remove the oil pump, first remove
top or bottom ofthe piston. for removal ofthe worm gear (13). The the clutch cover and chain brake (Fig.
Install the piston ring into the piston main bearings (11) and seals (12) fit J114). Remove the guide bar, chain and
groove so ends of the ring conrectly en- bores in the crankcase halves (1 and 9). clutch assembly. Unbolt and remove
gage the locating pin in the groove. The Use suitable tools to remove and install the chain guide plate (16—Fig. J113)
locating pin prevents the ringfromro- new main bearings and seals. Lubri- and the oil pump housing (15). Lift the
tating and the ends of the piston ring cate lips of seals with engine oil before pump (14 and 18) and rubber connector
must fit around this pin. installing over the crankshaft. Make (17) from the housing. Use special tool
Lubricate the connecting ix>d lower sure that mating surfaces ofthe crank- (part No. 530 03 11-36) to remove the
bearing, cylinder bore, piston and ring. case halves are properly cleaned before drive worm (13). If necessary, pull the
Make sure the ends of the piston ring assembling. oil suction pipe (19) and filter (20) from
surround the pin located in ring groove, Refer to PISTON, PIN, RING AND the oil tank.
then gently compress the ring while in- CYLINDER paragraphs for installing Clean and inspect all parts, then re-
stalling the cylinder straight over the these parts. Make sure both main bear- place any that are damaged. Use the
piston. If the cylinder is twisted, the ings (11—Fig. J113) and seals (12) are worm gear special tool to install the
ring can catch in a port and lDreak the properly seated in the upper crankcase worm gear (13) on the crankshaft. Lu-
end ofthe ring. before installing the lower half (10). bricate the oil suction pipe (19) before
Make sure both main bearings inserting in oil tank. Make sure that
(11—Fig. J113) and seals (12) are prop- CLUTCH. Refer to Fig. J114. Tb re- the suction pipe is completely seated in
erly seated in the upper crankcase. move clutch, first remove clutch cover the tank housing.
Clean the mating surfaces ofthe crank- (8), bar and chain. The clutch hub (14)
case halves, then apply a thin even coat is attached to the right end of the en- CHAIN BRAKE. The chain brake is
of sealer to the mating surfaces. Install gine crankshaft with left-hand threads designed to stop the saw chain quickly
the lower crankcase half (9), The ma- (tum clockwise to remove). Prevent the should kickback occur. The chain brake
chined surface at the side of the lower crankshaft from turning by using an is activated when the operator's hand
crankcase half, near the seal, must be appropriate piston stopper. Unscrew strikes the hand guard (3—Fig. J114).
toward the fl5rwheel side of engine. the clutch assembly from the crank- Forward movement of the hand guard
Tighten crankcase screws (S) in a cross- shaft. Special tool (part No. 530 03 disengages the trigger assembly (5) al-
ing pattern evenly to the tort^ue listed 11-12) is available from the manufac- lowing the spring (6) to tighten the
in TIGHTENING TORQUE para- turer to unscrew the clutch hub from band (7) around the clutch dmm (16).
graph. the crankshaft. The clutch drum (16) The brake is released and the mecha-
Attach the engine to the lower hous- and chain drive sprocket can be with- nism is reset by pulling back on the
ing (21) and tighten the screws (23) in a drawn aft«r the hub and shoes are re- guard. Keep the chain brake clean and
crossing pattern to the torquo listed in moved. Do not lose needle bearing (17) free of sawdust and dirt accumulation.
the TIGHTENING TORQUE para- or washer (15). Remove the clutch cover (8) to inspect
graph. The clutch shoes (12) and hub (14) and service the brake assembly. To dis-
When assembling, be sure impulse are available only as an assembly, but assemble, push hand guard (3) forward
channel (8—Fig. J112) is in place in cyl- spring (13) is available separately. Re- to release the brake. Remove hand
inder. Install a new impulse t;ube if the new clutch shoes if thickness of the guard mounting screw and drive out
old tube is lost or damaged. Slide the in- shoes is less than 1 mm (0.040 in.) at pivot sleeves (1). Separate hand guard
take connector (7) onto the cylinder, the most worn part. The inside diame- from clutch cover. Remove cover plate
then install the carburetor and air ter of the clutch drum must not exceed (9). Carefully pry spring (6) out of cover.
cleaner housing. Install muffler so that 64.4 mm (2.534 in.). Inspect all parts Drive out pin (4) and remove trigger as-
exhaust outlet is turned upwards and for wear or damage and replace as nec- sembly (5) and brake band (7).
awayfromthe cylinder. essary. Inspect all parts carefully and install
After assembly is completed, the If shoes are removed from the hub, new parts as necessary. Install a new
manufacturer recommends ttiat the bar assemble the spring and one of the brake band if any part of the band is
and chain be installed and the engine shoes on the hub. Clamp the hub, the worn to less than 0.8 mm (0.032 in.)
run 2-3 minutes. Stop the engine and one installed shoe and spring in a vise, thickness.
allow to cool, then tighter^ cylinder position the second shoe on the hub, Lubricate all pivot points lightly
screws (10—Fig. J113) again to the cor- then use a screwdriver to carefully pry when assembling. Do not allow any lu-
rect torque. the spring in position over the second bricant to get on gripping surfaces of
shoe. When assembled, the coupling for the clutch drum or brake band. No ad-
CRANKSHAFT AND CONNECT- spring (13) should be in the middle of justment of chain brake system is re-
ING ROD. The crankshaft and con- one ofthe shoes. quired.
necting rod are available only as an Grease the needle bearing in the
assembly (8—Fig. J113); individual clutch drum lightly before installing REWIND STARTER. Refer to Fig.
components are not available. A shop the drum. Install the clutch assembly, J115. The starter housing (4) can be un-
experienced in servicing built-up tightening the hub to the torque listed bolted and the assembly removed from

Dlustrations couit«y Jofuered Power Products AB


317
JONSERED CHAIN SAW

the saw. Pull the starter rope out ahout


20 cm (8 in.) and hold the pulley (6) to
keep the rope from rewinding. Pull a
loop of rope from hetween the housing
Fig. J114—Exploded view of (4) and the pulley (6) into one of the
the chain brake and clutch as-
semblies. notches molded into the edge of the pul-
1. Pivot sleeves ley. Hold the loop and allow the pulley
2. Spring to turn slowly until the spring is com-
3. Hand guard
4. Pin pletely unwound.
5. Brake trigger mechanism Remove the retaining screw (7) and
6. Brake spring
7. Brake band washer, then lift the pulley (6) from
8. Clutch cover/brake bousing housing. The rewind spring (5) can be
9. Brake cover removed if necessary, but be careful to
10. Spring
11. Chain adjusting screw control the spring as it is removed to
12. Clutch shoes prevent injury.
13. Clutch spring
14. Clutch hub Clean and inspect parts for damage.
15. Plate Lubricate the recoil spring, then wind
16. Clutxh drum
17. Needle bearing spring (5) into the housing cavity in a
18. Washer clockwise direction beginning with the
outside coil. If detached, attach the
rope to the pulley and make sure the
knot is securely nested in the pulley. In-
sert the end of the rope through the
housing (4) and guide (3), then attach
handle (2). Wind the rope clockwise
onto the pulley (6).
15
Position the pulley over the post in
housing with a loop in the rope between
the housing and pulley, then preload
the recoil spring by turning the pulley
about 4 turns clockwise before releas-
ing the rope loop. Install washer and
screw (7).
Check for proper spring preload as
follows. With rope fully extended, it
should be possible to rotate the pulley
Fig. J115—Exploded view an additional 1/2 turn without causing
of the rewind starter as-
sembiy. the spring to bind. Allow the rope to re-
1. Starter rope wind and make sure the handle is
2. Handle pulled against the housing. If the
10 3. Rope guide spring binds, pull a loop in the rope be-
4. Starter housing
5. Rewind spring tween the housing and the pulley, re-
6. Rope pulley lease some spring preload (about 1
7. Screw
8. Starter pawl turn), then recheck. If the handle is not
9. Spring wound against the housing, increase
10. Flywheel
11. Nut the preload and recheck.
Inspect the condition of the pawl (8)
and spring (9) attached to the flywheel.
On some models, the pawl assembly
may be part of a plate attached by the
flywheel retaining nut.

Illustrations courtesy Jonsered Power Products AB


318

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