Workshop manual Jonsered 2141/2145/2150
Contents
1. ccceececeeeeeeeeeeseteeeeeees 36 Air intake system nananana nnnanwwnawannnnnnaans 37 Carburettor adjustment 1 1111 aasa 39 Pugita namn Aa anan 41 Fuel filter nanana nananana kan anna aman anan 42 Fuel hose 0000 cee ce cece eee eeeeeeeeceeeeeeeeeeeeeeeeeeeeeaneaees 42 Piston and Cylinder 0 0 0 2 ceeeeeeeeeeeeeeeeeeeeeeeeeees 43 Decompression valve pressure testing 45 Cylinder pressure testing 00 ccceeeeeeees 47 Crankcase and crankshaft 0 cceeeeeeeees 48 Crankshaft bearings ccceeeeeeeeeeeeeeeeeeeees 49 Repairing damaged threads 000eeee 51 Guide bar bolts mana nananana wana nwawannawaaannawannan 51 Appendix A Carburettor EPA models 52 English 1 Introduction Arrangement of the manual This workshop manual can be used in two different ways To repair a specific sub assembly on a chainsaw To dismantle and reassemble a complete chainsaw Repairing a specific sub assembly If a specific sub assembly on the chainsaw needs to be repaired 1 Look up the page referring to the relevant sub assembly 2 Follow the instructions under the headings Removal Dismantling Cleaning and inspection Refitting Reassembly Dismantling and reassembling the entire chainsaw If the entire chainsaw is to be dismantled follow the instructions under the heading Removal Dismantling Work through the manual and fo2. 5 Remove the high low and idling jet screws HDA 159A high and low jet screws are protected by plastic caps which can be prised off with a screw driver Only on EPA see appendix A 6 Remove the plug by first drilling a hole in it and then prising it out with a screwdriver or the like 7 If necessary remove the throttle and choke valves and remove the spindles together with the lever arms and springs Cleaning and inspection Clean all the carburettor components in petrol Use an airline to dry off the petrol from all components Blow through all the channels in the carburettor body and check that they are not blocked Check that The gasket pump diaphragm and metering diaphragm are undamaged There is no play in the throttle and choke valves The needle valve and its lever arm are not worn The fuel filter is undamaged The tips of the high and low speed jet screws are not damaged The air intake duct is not cracked Carburettor reassembly NOTE Cleanliness is very important when reas sembling the carburettor Tiny particles of dirt can cause operating problems The item numbers in the diagram refer to the steps below 1 8 English 33 Repair instructions 1 If the throttle and choke butterflies and their spindles were removed these must be refitted Lubricate the spindle bearings with light oil 2 Insert the plug in the hole with the convex side upwards an
3. NOTE If the chain turns at idling speed the T screw should be turned anti clockwise until the chain stops Fine adjustment Once the chainsaw is run in the carburettor should be readjusted First adjust the L jet screw then the idling screw T and finally the H jet screw The recommended engine speeds are as follows Model Max revs ldle revs 2149 W 13 000 rpm 2 700 rpm 2141 12 500 rpm 2 700 rpm 2145 12 500 rpm 2 700 rpm 2150 12 500 rpm 2 700 rpm 2159 13 500 rpm 2 700 rpm Basic requirements Before making any adjustments the air filter should be clean and the cylinder cover should be in place If the carburettor is adjusted with a dirty air filter the mixture will be too weak next time the air filter is cleaned This can cause serious engine damage e Carefully screw in the L and H jets fully then back them off 1 turn The carburettor now has the settings H 1 andL 1 e Start the chainsaw and allow it to warm up for 10 minutes Place the saw on a flat surface so that the guide bar is pointing away from you and the guide bar and chain are not touching the surface Low speed jet L e Find the highest idling speed by slowly screwing the L screw in and then out again e When the highest speed has been found screw out the L screw 1 8 1 4 turn 40 English Fine adjustment of idling speed T The idling speed is adjusted using the screw marked T e If adjustment is necessary scre
4. e silencer spark plug fuel tank applies to 2141 2145 Unbolt the vibration damping spring from the hand grip Se sl Sp 7 Undo the four cylinder bolts and lift the cylinder off carefully Models 2141 2145 Undo the four cylinder bolts from the underside and lift the cylinder off carefully English 43 Repair instructions 4 Cover the opening in the crankcase Remove the circlips from the ends of the gudgeon pin and press it out Then lift off the piston Remove the bearing from the little end of the connecting rod 7 K A Se Ci VA II If replacing the cylinder Unscrew the decompression valve Remove the intake system see Air intake system removal 44 English When replacing the cylinder 2141 2145 Unscrew the decompression valve 2145 Remove the intake system see Air intake system removal Model 2150 is fitted with a spacer which is se cured using four bolts from the underside The spacer does not however need to be removed when removing the cylinder Cleaning and inspection Clean all the components scraping off all traces of old gasket and carbon from the following places e Piston crown Top of the cylinder bore e Cylinder exhaust port Decompression valve channel 2149 2145 2150 e Cylinder base and or crankcase Check the following The surface coating of the cylinder is not worn through
5. the saw must be run for the first 3 4 hours with carburettor adjusted to the factory settings Cylinder pressure testing OW NG XO EG as iS EB Loosen the carburettor bolts so that the carbu rettor can be moved back about 4 mm Insert cover plate 502 54 11 02 between the carburet tor and the carburettor flange Tighten the carburettor bolts to a torque of 1 1 5 Nm e Loosen the silencer bolts so that the silencer can be moved back about 4 mm Insert cover plate 502 54 11 02 between the silencer and the exhaust flange on the cylinder flange Tighten the silencer bolts to a torque of 8 10 Nm e Unscrew and remove the spark plug Screw in pressure test nipple 503 84 40 02 Connect tool 502 50 38 01 to the nipple The decompression valve must be closed The decompression valve must be closed To check the decompression valve itself see Decompression valve pres sure testing Pump up the pressure to 80 kPa 0 8 bar Wait 30 seconds The pressure should not be less than 60 kPa 0 6 bar Remove the cover plates from the silencer and carburettor tighten the bolts to the specified torque Remove the pressure test nipple 503 84 40 02 and refit the spark plug WARNING AN After pressure testing the cylin der check that the inlet manifold is seated correctly otherwise the saw may be damaged English 47 Repair instructions Crankcase and crankshaft 3 dismantling 21
6. 0 5 ban The pressure should drop to 20 kPa 0 2 bar within 60 seconds 2 Use gauge 502 50 37 01 to measure vacuum Readings should be as follows the vacuum should increase from 30 to 15 within 30 seconds If readings are outside this range the vyon plugs must be replaced Fuel tank refitting 1 Insert the fuel hose into the carburettor chamber Refit the fuel tank Bolt the front vibration damping spring into posi tion followed by both stops and the remaining two vibration damping springs Tighten to a torque of 2 3 Nm Check that both vibration damping springs and the stops are correctly seated on the crankcase Incorrect fitting may result in higher vibration levels Repair instructions Fit the throttle pushrod in the tank and connect it to the carburettor Refit the spring Connect the fuel hose to the carburettor Check that the hose is not kinked or too long to be clamped between the crankcase and tank The correct hose length between the tank and crank case is 43 mm 1 69 inches The correct hose length between the crankcase and carburettor is 53 mm 2 09 inches excluding the mitred section 5 Connect the fuel hose to the carburettor 6 Then refit cable guide starter assembly 2 5 3 Nm e chain and guide bar e clutch cover air filter e cylinder cover Piston and cylinder removal 1 Remove e cylinder cover e carburettor see Carburettor removal
7. Construction and function In part throttle mode the throttle valve F is par tially open Fuel is supplied through the diffuser jets E In full throttle mode both valves are open and fuel is supplied through all the diffuser jets E English 9 Troubleshooting The various faults that can affect a chainsaw are divided into four groups In each group the likely symp toms are given on the left and possible causes are listed on the right The most likely faults are given first and so on Starting Difficulty starting Adjust L screw Air filter blocked Choke not working Worn choke pivot Worn choke valve Fuel filter blocked Fuel line blocked Piston ring seized Blocked impulse channel Carburettor leaking fuel Loose or faulty fuel pipe Hole in diaphragm Worn needle valve Needle valve assembly sticking Needle valve set too high Leak in metering system air or fuel Loose cover on carburettor pump side Worn needle valve Needle valve set too high Needle valve assembly sticking Flooding when engine not running Idling low rpm Will not idle Adjust L screw Leaking air intake hose rubber Loose carburettor mounting bolts Loose or faulty fuel hose Fuel filter blocked Fuel line blocked Fuel tank vent blocked Throttle valve pivot stiff Throttle pushrod sticking Defective throttle return spring Bent throttle stop Faulty diffuser jet Idling too rich Adjust L screw Worn needle valve
8. Crankshaft bearings replacement 2149 If the crankshaft bearings are to be replaced tap them out gently using drift 502 70 84 01 The new bearings must be shrunk fit into the crankcase using a hot air gun Cleaning and inspection Clean and inspect all parts carefully Sealing ring replacement Remove the sealing ring from the magnet side using tool 502 50 55 01 Sealing ring replacement drive side Remove the oil pump 1 Pry up the sealing ring from the bearing by using a small screwdriver or the like Note The sealing ring can be replaced without the need of removing the bearing 2 Press the new sealing ring into the bearing English 49 Repair instructions Crankshaft bearings replacement 2159 If the crankshaft bearings are to be replaced they must be pulled off the crankshaft using puller 504 90 90 02 The new bearings must be shrunk fit into the crankcase using a hot air gun Heat the crank case half to around 130 C and fit the new bearing The new bearings must be shrunk fit into the crankcase using a hot air gun Cleaning and inspection Clean and inspect all parts carefully Sealing ring replacement Remove the sealing ring from the crankcase using a small screwdriver NOTE Take care to avoid damaging the crank case To fit the sealing ring use the sleeve that is sup plied with 502 50 30 16 The end with the half moon is used for the sealing ring on the
9. Remove the cylinder cover Disengage the chain brake by pushing the kickback guard backwards Undo the guide bar bolts and remove the clutch cover chain and guide bar Disconnect the HT lead Remove the spark plug and fit piston stop 502 54 15 01 in its place Unscrew the clutch clockwise using clutch tool 502 54 16 01 anda suitable socket spanner or combination spanner use tool 502 52 22 02 for model 2159 3 Models 2141 2145 2149 2150 D Unbolt and remove the clutch drum A RIM chain sprocket B if fitted needle bearing C and pump drive wheel D 28 English Model 2159 Loosen the chain guide plate one or two bolts depending on the model Model 2150 Remove the bolts on the anti vibration elements on the same side 5 Unbolt the oil pump from the crankcase Repair instructions Remove the oil hose and filter A Model 2159 has two oil hoses Model 2150 Push the housing up a little from the fuel tank and remove the filter A from underneath see the diagram under Oil pump removal 2141 2145 7 Remove the pin B from the adjuster screw using a small drift to press it out 8 Press in the pump piston C so that the adjuster screw D can be removed Remove the pump piston Oil pump removal 2141 2145 1 4 See Oil pump removal models 2149 2150 points 1 4 Remove the bolts on the anti vibration elements on the same side N NG si TY ARN Carefu
10. especially in the upper part of the cylinder The cylinder is free from score marks and areas of wear e The piston is free from score marks Small scratches can be polished out with fine emery paper The piston ring is not burnt into its groove Repair instructions e Measure piston ring wear This should not exceed 1 mm Use the piston to push down the piston ring The needle roller bearing is undamaged The inlet manifold is undamaged e Pressure test the decompression valve Also refer to Jonsered s Analysis guide for piston failures art no 108 07 01 01 Decompression valve pressure testing 1 Connect tool 502 50 38 01 to the decompression valve 2 Pump up the pressure to 80 kPa 0 8 bar 3 Wait 30 seconds 4 The pressure should not be less than 60 kPa 0 6 bar Piston and cylinder refitting 2149 2150 2159 T O gt Al Fo 3 177 NG p 4 aV TINN Lubricate the little end bearing with two stroke oil and insert it in the connecting rod KU 4 Fit the piston with the arrow pointing towards the exhaust port Push in the gudgeon pin and fit the circlips If replacing the cylinder fit the decompres sion valve tightening to a torque of 12 14 Nm English 45 Repair instructions Fit the inlet manifold 503 86 63 01 to the cylinder Check that the impulse tube is correctly seated in the impulse channel NOTE It is very important that th
11. 6 English Technical data Cylinder bore mm Q inches 44 0 1 73 40 0 1 60 42 0 1 65 47 0 1 85 Ignition system FHP CD FHP CD FHP ET Chain speed at max power revs m s rpm 17 3 9 000 17 3 9 000 20 9 000 Stroke mm inches 32 5 1 28 32 5 1 28 32 5 1 28 34 1 34 a Ce Air gap mm inches 0 3 0 012 0 3 0 012 0 3 0 012 Chain pitch mm inches 8 25 0 325 8 25 0 325 8 25 0 325 9 52 3 8 Max power speed kW hp rpm 2 3 3 1 9 000 2 0 2 7 9 000 2 2 3 0 9 000 3 0 4 1 9000 Carburettor type Walbro HDA 154B EPA Walbro HDA 159A Walbro HDA 154B EPA Walbro HDA 159A Walbro HDA 174 EPA Walbro HDA 175 Drive link mm inches 1 3 0 050 1 5 0 058 1 3 0 050 1 5 0 058 1 5 0 058 Technical data _ Idling speed Engagement speed Max speed rpm rpm rpm 2149 W 2 700 3 800 13 000 2141 2145 2150 2 700 3 800 12 500 2159 W 2 700 3 800 13 500 Sas KOO Su Fuel tank capacity Oil pump capacity at Oil tank capacity Litres US pints 8 500 rpm Litres US pints ml min 2149 W 0 5 1 06 5 10 0 28 0 59 2141 2145 2150 0 5 1 06 9 0 25 0 53 2159 W 0 7 1 27 5 15 0 38 0 69 Gy SU o D Weight without bar and chain Weight with bar and chain kg Ibs kg Ibs 2149 4 9 10 8 5 7 12 4 2149W 50 110 5 8 12 4 2141 2145 2150 4 9 10 8 5 7 12 4 21
12. a saw do not touch the silencer until it has cooled down The silencer gets very hot and you may burn yourself Wear protective gloves when working on the silencer 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 com pression 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 English 3 Special tools 1 2 4 English Special tools Item Description Used for Order no 1 Clutch tool Centrifugal clutch 502 54 16 01 2 Piston stop Locking crankshaft 502 54 15 01 3 Stop plate Locating intake gaiter 502 54 17 01 4 Fuel filter hook Withdrawing the fuel filter 502 50 83 01 5 Allen key For M5 bolts 502 50 18 01 6 Puller Frame bea
13. clutch side which must be fitted flush with the surface of the crankcase The other end of the sleeve is used to fit the sealing ring on the flywheel side and ensures that the sleeve is fitted at the correct depth 1 8 mm Lubricate the sealing rings with oil 50 English Crankshaft bearings 2141 2145 2150 replacement Remove The crankshaft complete from the crankcase see page 47 CAN N 1 Pull off the crankshaft bearing from crankshaft 2 Fit a new bearing on the crankshaft Repair instructions Crankcase and crankshaft reassembly 2149 Hold the clutch side of the crankcase in a vice Pull the crankshaft into its bearing using assembly tools 502 70 84 01 and 502 70 45 07 Check that the guide pins are in place Fit a new gasket to the mating surface of the clutch side of the crankcase 3 Place the flywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 502 70 84 01 and 502 70 45 06 Fit and tighten the six crankcase bolts to a torque of 8 10 Nm Check that the crankshaft rotates freely nadi the following parts e bark rest oil pump e chain tensioner centrifugal clutch e fuel tank e piston and cylinder generator e carburettor base e carburettor throttle pushrod silencer e ignition system starter assembly e cylinder cover
14. e clutch cover guide bar and chain See special instructions NOTE lf a new crankshaft has been fitted the saw must be run in for 3 4 hours with the carburettor adjusted to the factory set tings English 51 Repair instructions Crankcase and crankshaft reassembly 2159 Hold the clutch side of the crankcase in a vice Pull the crankshaft into its bearing using assembly tools 502 50 30 16 Check that the guide pins are in place Fit a new gasket to the mating surface of the clutch side of the crankcase 3 Place the flywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 502 70 84 01 and 502 50 30 16 52 English Fit and tighten the six crankcase bolts to a torque of 8 10 Nm Check that the crankshaft rotates freely 5 Refit the following parts bark rest 8 10 Nm e oil pump 3 4 Nm see Oil pump refitting e chain tensioner e centrifugal clutch min 20 Nm see Centrifugal clutch refitting e fuel tank see Fuel tank refitting e piston and cylinder see Piston and cylinder refitting generator see Replacing the generator carburettor base 3 4 Nm e carburettor 1 1 5 Nm see Carburettor refit ting throttle pushrod e silencer 12 14 Nm see Silencer refitting e ignition system 8 10 Nm see Ignition module and flywheel refitting e starter a
15. inspection e 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 e Lubricate the throttle lock with oil e Check that the spring is not broken and has not lost its tension Throttle lock throttle trigger and return spring refitting Refit the return spring to the throttle trigger as shown Make sure the spring is correctly positioned by engaging one end in the slot in the throttle trigger A 2 First insert the rear edge of the throttle trigger into the tank Then push clip the front edge into the two clips on the tank with the aid of a combination tool for example Drive in the steel pin from the clutch side Use a 2 5 mm 0 1 diameter drift 3 Then press down the return spring while pressing the throttle lock forwards upwards into the retaining clip in the fuel tank until you hear a click Release the return spring in the throttle lock then press the lock down onto the tank 4 Check the operation of the throttle lock by trying to press the throttle trigger without pressing down the throttle lock Also check that the throttle lock and throttle trigger return freely to their original posi tions when released English 17 Repair instructions Hand grip heater on model 2149W 2159W removal No heating or heating only in front hand grip Front hand grip troubleshooting Remove the three bolts that
16. it upwards without pulling it through the rubber inlet manifold Carefully release the carbu rettor assembly from the right hand rubber mount ing and lift it upwards 3 Compress the clip that holds the choke control to the carburettor while pulling it out at the same time Disconnect the choke control from the air filter holder Repair instructions Choke control refitting First reattach the choke control to the air filter then press it onto the carburettor so that the clips engage Then refit e stop switch e carburettor into its rubber mountings e throttle pushrod into the fuel tank and connect to throttle lever e lift the spring arm over the throttle pushrod fuel hose to the carburettor air filter and cylinder cover Throttle lock throttle trigger and return spring removal Remove the throttle lock by pressing it to the left A and carefully levering it up with a screwdriver on the clutch side B of the saw to disengage the lugs on either side of the throttle lock from the fuel tank When both lugs are clear of the tank pull the lock backwards C Drive out the steel pin using a 2 5 mm 0 1 diam eter drift A Push it out from the flywheel side of the saw Remove the throttle trigger by first press ing it towards the clutch side of the saw B until it clicks then towards the flywheel side until it clicks again Remove it from the tank and lift out the return spring Cleaning and
17. or complete carbu rettor 1 Screw the new H needle to the bottom and turn it counterclockwise 3 4 turns 2 Check that The H cap is adjusted to its richest setting Turned counterclockwise to stop The cap is not fixed to the needle it should rotate independently Adjust the L cap to a center position 1 4 turn counterclockwise minimum 1 4 turn clockwise maximum 3 Start the engine If necessary adjust the idling speed with the T screw until the chain stops 4 Adjust the H needle to give a top speed of A rpm Model 2149 W A 12 000 Use a narrow blade screwdriver Ref no 531 00 48 63 and insert it through the hole in the cap max blade width 2 mm 0 08 inch 5 Let the engine run at 12 000 rpm 1 minute until warm 6 Adjust the H needle to a top speed of B rpm Model 2149 W B 13 000 7 Check that the H cap is still adjusted to its richest setting Turned counterclockwise to stop NOTE The H needle must not rotate 8 Gently knock the H cap into position Use a 5 mm 0 2 inch mandrel for ex the locking pin for the bevel gear ref no 502 02 61 03 This is a basic carburettor adjustment Further fine adjustments within the limits the caps allow may be necessary to achieve optimum performance See the Operator s manual Replacement of the L needle 1 Take off the cap from the L needle e g a pair of cutting pliers and unscrew the needle 2 Screw the new L needle to the bott
18. plate in the carburettor flange cut out B and check that the insulating plate s impulse tube sits correctly in the inlet manifold Fit the perforated brass support ring in the inlet manifold Fit the air intake system on the cylinder and snap the insulating plate into position Check carefully that the impulse tube is correctly seated against the cylinder s impulse channel 3 Position tool 502 54 17 01 between the carburettor flange and the insulating plate Repair instructions Refit the carburettor Screw in the carburettor bolts directly from behind without lifting the carbu rettor assembly tightening to a torque of 1 1 5 Nm It is important to hold the carburettor flange securely when tightening the bolts to prevent the inlet manifold from moving Push down the rear carburettor mounting into the rubber bushings using a small screwdriver Remove tool 502 54 17 01 5 Refit cylinder see special instructions e silencer support does not apply to 2141 2145 2150 air filter HT lead e cylinder cover after the test run retighten the silencer bolts to a torque of 8 10 Nm Carburettor adjustment For instructions on adjusting the EPA carburettor see appendix A Adjusting the carburettor involves adjusting the engine to the local conditions e g climate altitude fuel and type of two stroke oil The carburettor is equipped with three adjustment options L Low speed jet H Hig
19. secure the cover over the front hand grip Disconnect the leads from the switch and generator and measure the resistance of the hand grip heater which should be 3 4 ohm Replace the front hand grip if the resistance is higher 2 Reconnect the leads and refit the cover 3 Push the switch back into place and reconnect the leads 4 Bolt the cover back onto the hand grip 18 English e Generator troubleshooting 1 Remove the cylinder cover and cover from the front hand grip Disconnect the black lead from the generator and connect a multimeter between it and a clean area on the cylinder The multimeter should show a resistance of 0 9 1 3 ohm If the reading is higher or lower replace the generator see Re placing the generator 2 Reconnect the lead and refit the hand grip cover and cylinder cover e Switch troubleshooting 1 Carefully free the switch and frame from the front hand grip using a screwdriver 2 Disconnect the leads from the switch and connect a multimeter to it The meter should read over 1000 ohm when the switch is in the O position The meter should read no higher than 0 1 ohm with the switch in the 1 position Replace the meter if the readings are outside these limits Rear hand grip heater not working Rear hand grip heater troubleshooting 1 Remove the cylinder cover air filter and cover from the rear hand grip 2 Disconnect the red lead from the
20. the rear tank mounting from the crankcase i e the rear vibration damping spring and both stops Lower the tank as far as it will go to allow access to the heater lead where it is connected to the tank 5 Disconnect the generator lead from the hand grip and unclip it from the tank Remove the generator and lead Generator refitting 1 Feed the generator lead through the holes in the crankcase and hand grip Bolt the generator in position tightening the bolts to a torque of 5 Nm Clip the lead to the tank NOTE The lead connector must be positioned on the right of the clip see diagram Connect the lead to the connector on the hand grip 2 Refit e fuel tank with both stops and rear vibration damping spring e fuel hose to carburettor hose length between tank and crankcase 43 mm 1 69 inches and between crankcase and carburettor 53 mm 2 09 inches e throttle pushrod to carburettor e flywheel with nut and washer cable guide leads and starter assembly Remove the piston stop and reconnect the HT lead and cylinder cover Repair instructions Ignition module and flywheel refitting Place the flywheel on the crankshaft Turn the flywheel so that the key lines up with the keyway in the shaft Fit the washer and nut on the shaft and tighten to a torque of 25 30 Nm To refit the ignition module proceed as follows Turn the flywheel so that the magnets are in line with the ignition module Fit the ign
21. 49 2159 1 Remove the following e guide bar and chain clutch cover cylinder cover fal T o Gi e ignition system p generator JO CG centrifugal clutch starter assembly oil pump bark rest Split the crankcase with the aid of tool 502 51 61 01 A and stop plate 502 54 18 01 B working e chain tensioner from the flywheel side of the saw throttle pushrod 4 e carburettor e carburettor base e silencer e piston and cylinder fuel tank See special instructions NOTE Take care to prevent dirt or foreign parti cles getting into the bearings Press the crankshaft out of the flywheel side of the crankcase using tool 502 51 61 01 5 Do the same on the clutch side without using stop plate 502 54 18 01 Unscrew the 6 bolts that hold the crankcase together 48 English Repair instructions Crankshaft complete dismantling 2141 2145 2150 1 Remove the following e chain and bar clutch cover e cylinder cover e starter assembly e ignition system generator e centrifugal clutch e throttle pushrod e carburettor e silencer piston and cylinder e fuel tank See special instructions Lift the crankshaft completely out of the crankcase 2150 Unbolt the four bolts from underneath and lift off the spacer Lift the crankshaft completely out of the crankcase
22. 59 5 6 12 4 6 4 14 1 2159 W 5 7 12 6 6 5 14 3 Spark plug Bosch RCJ 7Y NGK BPMR 7A NGK BPMR 7A Champion RCJ 7Y NGK BPMR 7A Champion RCJ 7Y Automatic oil pump Yes Yes Yes Heated hand grips Yes Ja English 7 Construction and function Carburettor The carburettor consists of three sub systems The metering unit A which contains the jets and the fuel control mechanism This measures out the right amount of fuel to suit the speed of the saw and the power demand The mixing unit B consists of the choke diffuser jets and throttle valve This is where the air and fuel are mixed to create a flammable mixture The pump unit C pumps fuel from the tank to the metering system inside the carburettor One side of the pump diaphragm is connected to the crankcase and pulses as a result of pressure changes in the crankcase The other side of the diaphragm sucks in the fuel 8 English The carburettor works in different ways depending on the setting e Cold start mode e Idling mode Part throttle mode Full throttle mode In the cold start mode the choke valve D is completely closed This increases the vacuum in the carburettor so that fuel is sucked through the diffuser jets faster E In idling mode the throttle valve F is closed Air is sucked through an aperture in the throttle valve and a small amount of fuel is supplied through the diffuser jet E
23. Needle valve set too high Worn needle valve lever Leaking control diaphragm cover plate Needle valve assembly sticking 10 English Idling low rpm cont Idles when L screw closed Idling uneven L screw requires constant adjustment Too much fuel at idling Worn needle valve Leaking control diaphragm cover plate Needle valve assembly sticking Worn needle valve lever Faulty diffuser jet Fuel filter blocked Fuel line blocked Leaking air intake hose rubber Loose carburettor mounting bolts Worn throttle valve pivot Loose throttle valve screw Worn throttle valve Needle valve assembly sticking Leak in metering system air or fuel Metering system centre knob is worn Hole in diaphragm Leaking control diaphragm cover plate Crankcase leaking Fuel line blocked Needle valve set too high Needle valve assembly sticking Leak in metering system air or fuel Leaking control diaphragm cover plate Faulty diffuser jets Crankcase leaking Needle valve set too high Needle valve assembly sticking Metering system damaged Worn needle valve Leaking control diaphragm cover plate Metering system incorrectly assembled Troubleshooting High rpm Low power Will not four Acceleration and retardation Does not Adjust L screw Blocked air filter Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel leaking Impulse channe
24. Repair instructions Carburettor refitting NOTE Cleanliness is very important when reas sembling the carburettor Tiny particles of dirt can cause operating problems Fit stop plate 502 54 17 01 between the carburet tor flange and the insulating plate 2 Fit the carburettor Screw in the carburettor bolts directly from behind without lifting the carburettor assembly Tighten to a torque of 1 1 5 Nm It is important to hold the carburettor flange while tightening the bolts to prevent the inlet manifold from moving GC ZR RL po ay HR Z Push the rear carburettor mounting into its rubber bushing using a small screwdriver Remove stop plate 502 54 17 01 Connect the fuel hose to the carburettor Refit the throttle pushrod at the same time as the rubber inlet manifold press in the throttle pushrod so that it engages in the carburettor and fit the spring Connect the leads to the stop switch English 35 Repair instructions Carburettor heater 2149 2159 Removing Remove carburettor 1 Remove the two screws from the clip above the carburettor Disconnect the leads from the carburettor heater and remove the heating element Heating element 36 English Carburettor heater 2149 2159 Refitting Heating element 1 Fit the heating element between the air filter connection and the carburettor as well as above the carburettor 2 Tighten t
25. Workshop manual 108 88 08 26 Workshop manual Jonsered 2141 2145 2150 2149 W 2159 W Contenis INI dUG NO Nanana IA kahinuih inah 2 Safety regulations 22 nanana nnnwwwananawann 3 General instructions aaa nnawawannwwwannwwwananana 3 Special instructions ccccceceeeeeseeeeseeeeeseeees 3 Special tools irasra neigia rasa eriat 4 Technical data oe en sain iai asie raadi 6 Construction and function 0 cceeeeeees 8 Carburettor seno e AE 8 Troubleshooting cccccceeeeeeeeeenteeeeeeeeaes 10 Repair instructions 0a ea 12 Chain brake eceecccceeesseeceeeecsaeeeeeessnaeeeeeessaees 12 Silence aa a anakan N 14 Chain catcher cccccccceessceceseeeseeeeeeesnseeeeeeeaas 14 StOp Switch iin aata e aaa ad 15 Stop switch resistance measurement 15 Choke control PAA iae era 16 Throttle trigger anannawwwaannnnawwwannnnnnnaaans 17 Hand grip heater ee eeeeeeeeeeeeeeeeeeeeeeeeees 18 Starter assembly cece cette eeeeeeeteeeeeeeeees 20 Starter cord aa AA KANAN eae 21 Recoil Spring eienen nta e tees 21 Ignition module testing aman nanasa 22 Ignition module and flywheel 0 eee 23 eneral0 serrr ka a AG 24 Centrifugal clutch eee eeeeeeeeeeeeeeteeeeneeees 26 Oil PUMP naaa AG Mia aie 28 CArUr EO Na ANNA 32 Carburettor pressure testing 34 Carburettor heater
26. aft and tighten anticlockwise as far as it will go Then tighten to a torque of at least 20 Nm using tool 502 54 16 01 and a suitable socket spanner or combination spanner use clutch tool 502 52 22 02 for model 2159 8 Remove the piston stop Fit the spark plug tighten ing it to a torque of 15 Nm then connect the HT lead Then refit the cylinder cover guide bar chain and clutch cover 9 Refill the tank with oil For more information see the user instructions for this model for the recom mended grade of oil Oil pump refitting 2141 2145 Lubricate the piston pump C with chain oil and fit the pump piston 2 Fit the pump A round pin secures its position Push the crankcase up a little from the fuel tank and screw on the filter A from underneath 3 Fit the chain guide plate one bolt tightening torque 2 3 Nm NOTE Check that the chain tensioner is in posi tion Fit the bolts on the anti vibration elements Note Models 2145 and 2150 have another type of chain tensioner which is adjusted from the side 4 See Oil pump Refitting models 2149 2150 2159 pos 6 9 Adjustable oil pump adjustment 2149 2150 2159 Use a screwdriver or adjustable spanner to turn the adjuster screw on the pump Turning the screw clockwise decreases the oil flow and turning it anti clockwise increases the oil flow Recommended setting 13 15 bar Min setting 15 18 bar Midway settin
27. d lift off the pulley 3 Models 2141 2145 2149 2150 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 Model 2159 Cleaning and inspection e Clean and inspect all parts carefully If there are any cracks or other defects replace the dam aged parts with new ones Lubricate the return spring with light oil Tensioning the recoil spring 1 Models 2141 2145 2149 2150 Fasten the starter cord in the notch in the pulley rim and wind the pulley about 2 turns clockwise Check that the pulley is free to rotate at least another half turn when the starter cord is fully extended Model 2159 English 21 Repair instructions Replacing a worn recoil spring WARNING Make sure the recoil spring does not fly out and cause injury Wear eye protection Remove the bolt from the centre of the pulley and lift off the pulley and spring 2 Remove the broken recoil spring For model 2159 remove the recoil spring cassette 3 Models 2141 2145 2149 2150 Fit a new recoil spring with the retaining wire still in place Do not remove the wire until the spr
28. d expand it by pressing downwards with a drift 3 Refit the high and low speed jet screws and springs plus the idling screw Fit the plastic caps over the high and low speed screws 4 Fit the fuel filter using the handle of a small screw driver 5 Fit the pump diaphragm gasket and cover to the pump unit 6 Fit the needle valve with lever arm spindle and spring and tighten the screw Use a rule to check that the lever arm is level with the cover face If necessary the lever arm can be bent slightly 7 Fit the metering diaphragm with its gasket and refit the cover to the metering unit 8 Carry out pressure testing 34 English Carburettor pressure testing Pressure testing should be carried out with the carburettor fully assembled Testing should always be carried out after the carburettor has been repaired but can also be performed for trouble shooting before dismantling Carry out the test as follows e Screw in the high and low speed jet screws and back them off one turn Connect pressure tester 502 50 38 01 to the carburettor fuel inlet Lower the carburettor into a beaker of water Pump up the pressure to 50 kPa 0 5 bar and clamp the pump tube There should be no leakage If leakage occurs refer to the table below Leakage Fault lies in Diffuser jets Needle valve In impulse tube Pump diaphragm Ventilation hole above metering unit Control diaphragm
29. e assumed to have general experience of repairing and servicing chainsaws Workshops where chainsaws are repaired must be equipped with safety equipment that meets local regulations No one should carry out repairs on a chainsaw until they have read and understood the contents of this workshop manual Chainsaws are type approved to meet the relevant safety legislation but this only applies when the saw is fitted with the cutting equipment specified in the user s manual The fitting of any other equip ment or of accessories or parts that are not approved by Jonsered could mean that the saw no longer meets these safety requirements and the person who carried out the work may be held responsible for its non conformance In this workshop manual the following boxes indicate where caution should be taken WARNING The warning text warns of the risk of personal injury if the instruc tions are not followed AN NOTE The warning text warns of the risk of material damage if the instructions are not followed Special instructions The fuel that is used in a chainsaw poses the following hazards The fuel and its fumes are toxic e May cause irritation to skin or eyes e May cause breathing difficulties e Highly flammable When using compressed air the air jet should never be pointed at the body Air can be forced into the bloodstream and cause fatal injury Wear ear protection when testing saws After testing
30. edle valve set too low Metering system incorrectly assembled Needle valve assembly sticking Faulty diffuser jets Blocked silencer Adjust L screw Adjust H screw Faulty pump diaphragm Needle valve set too high Needle valve assembly sticking Faulty diffuser jets Engine stalls Adjust L screw Adjust H screw Blocked air filter Faulty pump diaphragm Faulty diffuser jets Over rich acceleration Troubleshooting methods In addition to the faults described in the above table trouble shooting can be carried out on specific components or sub systems of the chainsaw The various procedures are described in the relevant chapters see the contents page as follows e Checking the operation of the chain brake e Measuring the resistance of the stop plate e Pressure testing the carburettor e Pressure testing the decompression valve e Pressure testing the cylinder English 11 Repair instructions Chain brake dismantling 1 Disengage the brake by pushing the kickback guard backwards Unscrew the guide bar bolts and remove the clutch cover chain and guide bar Grip the clutch cover carefully in a vice Release the brake spring by using the kickback guard from the saw as a tool Engage it with the brake mecha nism and turn anticlockwise to activate the brake 12 English 3 WARNING Make sure the spring does not fly out and cause injury Wear eye protection Remove the screws a
31. eel wire until the bolt comes out through its hole 6 Pull through the bolt with its nut Place a spacer between the nut and crankcase 7 Check that the square shoulder of the bolt is correctly seated in the recess in the crankcase 8 Refill with chain oil 54 English Appendix A Carburettor EPA models Basic adjustment for EPA carburettors After replacing the carburettor or high speed and or low speed needle on an EPA The US Environ mental Protection Agency certified product a basic adjustment must be carried out as described below in order to meet the EPA requirements This to achieve as low emissions as possible This instruc tion is made for USA only On EPA carburettors both the H and L needles are fitted with caps to prevent the chain saw operator from changing the adjustment above EPA stand ard The caps can be removed to achieve richer or leaner adjustments To set the needles correctly an adjustment sleeve is fitted over the caps to lock them in maximum allowed setting When correctly set the caps must be fixed on the needles The adjustment sleeve then can be removed NOTE Before making any adjustments the following must be done e Mount for this model approved bar 8 chain combination for a 16 bar see Technical data in the Operator s manual e The chain should not be tensioned more than that it remains 0 2 inches to the bar e Mount a new air filter Replacement of the H needle
32. ere are no leaks in the inlet system otherwise the engine may seize ANG y Press the insulating plate 503 86 62 01 onto the cylinder Check that the impulse tube connected to the insulating plate is seated correctly in the inlet manifold and lock the clamp over the manifold 5 Lubricate the piston ring and piston with two stroke oil 46 English Fit a new cylinder base gasket Compress the piston ring with tool 502 50 70 01 and lower the cylinder over it carefully 7 Fit the cylinder bolts tightening them in diagonal pairs to a torque of 8 10 Nm Repair instructions Piston and cylinder refitting 2141 2145 2159 1 5 See Piston and cylinder 2149 2150 2159 Refit ting points 1 5 6 Apply silicone adhesive sealing compound 03 7062 to the crankcase s contact surfaces with the cylinder Carefully slide the cylinder down over the piston towards the big end bearing Note Work is facilitated if the crankshaft complete with bearing and piston is released from the crankcase and the piston is pushed into the cylinder The unit is then refitted in the crankcase Fit the cylinder bolts tightening crosswise to a torque of 13 15 Nm 8 Pressure test the cylinder 9 Refit spark plug tighten to a torque of 15 Nm e carburettor see Carburettor refitting e silencer tighten to a torque of 8 10 Nm e cylinder cover NOTE If a new piston or cylinder has been fitted
33. g 18 20 bar Max setting English 31 Repair instructions Carburettor removal NOTE Do not use knurled pliers to disconnect or reconnect the fuel hose This could dam age the hose and lead to leakage or fracture Remove the cylinder and air filter Disconnect the leads from the stop switch and the fuel hose from the carburettor Disconnect the pushrod from the carburettor by first carefully prising up the spring over the end of the rod where it connects to the throttle lever A Then press the throttle lever forwards B while pressing the throttle pushrod backwards C and lifting it off the lever Withdraw the throttle pushrod from the tank and lift it upwards without pulling it through the rubber inlet manifold Carefully release the carburettor assembly from the right hand rubber mounting and lift it upwards 32 English Remove the rubber inlet manifold using a large screwdriver 4 Undo and remove the carburettor bolts Lift off the carburettor Repair instructions Carburettor dismantling The item numbers in the diagram refer to the steps below 1 7 1 Remove the cover from the metering unit and carefully remove the metering diaphragm and gasket 2 Undo the screw and take out the needle valve together with the lever arm spindle and spring 3 Remove the cover from the pump unit and carefully remove the gasket and pump diaphragm 4 Remove the fuel filter
34. h speed jet T Idling adjustment screw H aoe L T OS J f The L and H jets adjust the fuel flow to match the airflow that the throttle valve opening allows Turn ing them clockwise makes the fuel air mixture weaker less fuel in relation to the amount of air and turning them anti clockwise makes the fuel air mixture richer A weak mixture increases the engine speed and a rich mixture decreases the engine speed SZ Uy The T screw controls the throttle position when idling Turning the T screw clockwise gives faster idling turning it anti clockwise lowers idling speed WARNING The guide bar chain and clutch cover must be fitted before the saw is started otherwise the clutch may fly off and cause injury AN Basic settings and running in During testing at the factory the carburettor is adjusted to the basic factory settings The factory settings are H 1 turn and L 1 turn To ensure that engine components receive adequate lubrication running in the carburettor should be set to a somewhat richer fuel mixture for the chainsaw s first 3 4 running hours This is done by adjusting the maximum speed to 6 700 rpm less than the recommended maximum speed English 39 Repair instructions If it is not possible to check the maximum speed with a tachometer then the H jet should not be set to a weaker mixture than the basic factory setting The recommended maximum speed must not be exceeded
35. he bracket above the carburettor using the two bolts 3 Connect the leads to the carburettor heater Refit carburettor Repair instructions Air intake system removal The air intake system comprises e inlet manifold e insulating plate with clip e carburettor flange e impulse hose support ring 1 Remove e cylinder cover air filter e carburettor e HT lead starter assembly 2141 2145 e Fuel tank 2141 2145 Unbolt the vibration damping spring between the cylinder and hand grip Unscrew and remove the bolt from the silencer support Unscrew the four cylinder bolts Lift up the cylinder so that the intake system insulating plate is free of the crankcase 5 On models 2141 and 2145 there are cylinder bolts on the underside English 37 Repair instructions 5 Free the insulating plate from the cylinder by releasing the clamp using pliers Remove the complete air intake system 6 Remove support ring carburettor flange from the inlet manifold insulating plate Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones Always use original parts NOTE When replacing the impulse hose it must not be lubricated with oil or grease 38 English Air intake system refitting Fit the inlet manifold A through the insulating
36. heater and connect a multimeter between it and the black earth lead that is bolted to the bottom of the carburettor on the clutch side of the saw The meter should read 0 7 1 2 ohm If the reading is higher replace the heater element 3 Remove the air filter throttle pushrod rubber diaphragm and carburettor see Carburettor removal 4 Remove the bolt from the plate at the base of the carburettor to release the lead for the heater element Repair instructions Unscrew the three bolts from the front hand grip and remove the cover to reveal the leads Discon nect the red lead 6 Unscrew the two bolts from the right side of the rear hand grip Remove the throttle lock and throttle handle see Throttle trigger Pull out the heater element with the leads still connected Heater element and rear hand grip removal 1 Remove the cylinder cover hand grip cover hand grip and right hand stop Then remove e throttle lock throttle trigger and recoil spring see Throttle trigger fuel hose and throttle pushrod from the carburettor Unbolt the rear tank mounting from the crankcase i e the rear vibration damping spring and both stops Lower the tank as far as it will go to allow access to the heater lead where it is connected to the tank Refit fuel tank with both stops and the rear vibration damping spring e throttle lock throttle trigger and recoil spring see Throt
37. ing is in position If the spring comes loose when you put it in place wind it up from the outside working inwards Lubricate the recoil spring with light oil Model 2159 Lubricate the recoil spring with light oil Fit the new recoil spring and cassette Screw the cassette onto the cover using the two screws 4 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 22 English Starter assembly refitting Position the starter assembly on the crankcase and tighten the bolts to a torque of 2 5 3 5 Nm 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 e Connect a test spark plug 502 71 13 01 to the ignition lead and clip the test spark plug onto the cylinder Turn the engine over using the starter cord Ifthe test spark plug produces a spark the ignition module is OK Repair instructions Ignition module flywheel removal 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 Model 2149 Remove the cover from the hand grip If replacing the ignition module disconnect its leads and unscrew it The ignition modu
38. ition module with the plastic feeler gauge 502 51 34 01 held in position at the same time without tightening the bolts Connect the black earth lead to the front screw on the ignition module Adjust the gap between the ignition module and magnet to 0 3 0 1 mm The gap must be measured at either of the two lowest pegs on the ignition module Tighten the bolts to 4 5 6 Nm Connect the blue lead to the ignition module Then refit cable guide and press the leads into position HT lead starter assembly tighten to a torque of 2 5 3 5 Nm e cylinder cover English 25 Repair instructions Centrifugal clutch removal 1 Remove the cylinder cover Disengage the chain brake by pushing the kickback guard backwards Undo the guide bar bolts and remove the clutch cover chain and guide bar 2 Disconnect the HT lead Remove the spark plug and fit piston stop 502 54 15 01 in its place 3 Models 2141 2145 2149 2150 Unbolt the clutch using tool 502 54 16 01 anda suitable socket or combination spanner Turn the nut clockwise to remove it Model 2159 LE Use clutch tool 502 52 22 02 26 English 4 Models 2141 2145 2149 2150 NOTE Handle the clutch springs carefully If they are opened up too much they could damage the saw Carefully prise out the clutch springs with a screw driver Model 2159 Inspection and cleaning e Clean and inspect all par
39. l blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor mounting bolts Needle valve set too low Metering system damaged Metering system incorrectly assembled Leaking control diaphragm cover plate Needle valve assembly sticking Blocked silencer Adjust H screw Blocked fuel tank vent Blocked fuel filter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air filter Needle valve assembly sticking Leak in metering system air or fuel Metering system incorrectly assembled Loose diaphragm rivet Hole in diaphragm Leaking control diaphragm cover plate Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber 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 accelerate Adjust H screw Blocked air filter Blocked fuel tank vent Blocked fuel filter Fuel line blocked Loose or damaged fuel hose Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Leaking air intake hose rubber Loose carburettor mounting bolts Ne
40. le can be left in place if you are simply removing the flywheel Loosen the flywheel nut using a suitable socket and unscrew it until it is flush with the end of the shaft Position puller 504 90 90 02 over the magnets and counterweight on the flywheel Tighten 2 3 turns and tap the head of the puller with a metal mallet to release the flywheel Remove the puller nut and washer Lift off the flywheel Cleaning and inspection e Clean all parts especially the tapers on the flywheel and shaft e Check that the flywheel is not cracked or dam aged in any other way English 23 Repair instructions Replacing the generator model 2149W 2159W 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 Remove the cover from the hand grip 2 Loosen the flywheel nut using a suitable socket and unscrew it until it is flush with the end of the shaft Position puller 504 90 90 02 over the magnets and counterweight on the flywheel Tighten 2 3 turns and tap the head of the puller with a metal mallet to release the flywheel Remove the puller nut and washer Lift off the flywheel Unscrew the two bolts from the generator but leave the generator in place 24 English 4 Remove the fuel hose and throttle pushrod from the carburettor Unbolt
41. le trigger and throttle lock into position and check that they work correctly see Throttle trigger Bolt the vibration damping springs that hold the tank unit back in place and refit the cover over the front hand grip 20 English Starter assembly removal Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assembly Pull out about 30 cm of the cord and fasten it in the notch in the pulley rim Release the tension in the return spring by letting the pulley wind backwards slowly 3 WARNING If the recoil spring is still under tension when the pulley is re moved it can fly out and cause in jury Wear eye protection Remove the bolt from the centre of the pulley and lift off the pulley Repair instructions Cleaning and inspection Clean the parts and check the following The starter cord The teeth on the pulley lubricate with oil That the pawls on the flywheel are undamaged i e that they spring back towards the centre and move freely e Lubricate the return spring with light oil Replacing a broken or worn starter cord Before replacing a worn starter cord the tension in the recoil spring must be released Pull the starter cord out through the notch in the pulley rim and wind the pulley anti clockwise to release the tension in the spring 2 Remove the bolt from the centre of the pulley an
42. llow the instruc tions given in each section under the heading Removal Dismantling Then follow all the Cleaning and inspection instructions in each section Working from the back of the manual follow all the instructions under the headings Refitting Reassembly in reverse order Each of the sections covering removal dismantling and refitting reassembly include the relevant lubrication instructions and bolt torques for each stage of repair Construction and function This chapter gives a simple description of the chainsaw carburettor and its various parts 2 English Troubleshooting These pages describe the most common faults that affect a chainsaw They are divided into four different groups with the most likely faults de scribed first Repair instructions The section that describes how to repair the chainsaw consists of detailed step by step instruc tions It explains in detail the special tools lubri cants and bolt torques that are needed when working on each component This workshop manual covers the following chainsaw models 2141 2145 2150 2149 2149W 2159 2159W Safety regulations General instructions This workshop manual gives detailed instructions on how to troubleshoot repair and test a chainsaw This section also describes the various safety precautions that should be taken when carrying out repairs The workshop manual has been written for person nel who ar
43. lly lift out the oil pump from the crankcase Push the crankcase up a little from the fuel tank and remove the filter A from underneath Cleaning and inspection e Clean and inspect all parts carefully If there are any cracks or other defects replace the dam aged parts with new ones Always use original parts e Lubricate all moving parts with chain oil English 29 Repair instructions Oil pump refitting 2149 2150 2159 5 1 Lubricate the pump piston C with chain oil and fit the pump piston and washers Fit the chain guard plate tightening the bolts to a torque of 2 3 Nm 2 Press down the pump piston C Fit the adjuster Model 2150 an screw and spring so that the pin B can be ie aca on the anti vibration elements on the pressed into position 3 6 Reconnect the oil hose and filter A Models 2141 2145 2149 2150 Model 2150 Push the crankcase up a little from the fuel tank and screw on the filter A from underneath WARNING Poor chain lubrication can result in failure of the chain which could cause serious or fatal injury Model 2159 Bolt the oil pump to the crankcase The adjustable oil pump must be bolted to torque of 2 3 Nm 30 English Repair instructions Lubricate the needle bearing with grease Fit the pump drive wheel D needle bearing C chain sprocket B if fitted and clutch drum A 7 Fit the clutch onto the cranksh
44. n clutch cover NOTE After completing the repair the chain brake must be tested as described below Operating test The engine must not be running during the test Guide bar length Height 38cm 15 50 cm 20 e Hold the chainsaw over a firm surface The height of the guide bar above the surface is given in the table above Letgo of the front handle and let the chainsaw fall towards the surface When the guide bar hits the surface the chain brake must engage English 13 Repair instructions Silencer removal WARNING Do not touch the silencer until it has cooled down otherwise you may burn yourself Remove the cylinder cover silencer support silencer gasket and cooling plate 2 If the saw is fitted with a spark arrestor mesh this must also be removed Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts with new ones The spark arrestor mesh is best cleaned with a wire brush If the mesh is damaged it must be replaced If the mesh is blocked the saw will overheat and this will cause damage to cylinder and piston Never use the saw with a silencer that is in poor condition Always use original parts 14 English Silencer refitting 1 If the saw is equipped with a spark arrestor mesh this should be fitted first 2 Refit cooling plate gasket e silencer tighte
45. n bolts to a torque of 8 10 Nm e silencer support cylinder cover 3 Run the saw for at least 1 minute then retighten the silencer bolts to 8 10 Nm 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 Remove the chain catcher and replace it with a new one Check that the vibration damping spring locates correctly against the crankcase when you bolt the new chain catcher in position A worn damaged chain catcher on 2141 2145 or 2150 can be replaced with the same chain catcher as 2149 see figure above 3 Turn the chain tensioner anticlockwise as far as it will go Refit guide bar chain clutch cover Repair instructions Stop switch removal 1 Remove the cylinder cover and air filter 2 Disconnect both leads from the stop plate and stop switch Remove the stop plate by carefully sliding it over the lug on the front mounting Carefully prise the carburettor assembly off the left hand rubber mounting using a small screwdriver Carefully prise the stop switch s upper mounting off the air filter holder while lifting the switch to release it from the lower mounting Cleaning and inspection Clean and inspect all parts carefully If there are any cracks or other defects replace the damaged parts
46. nd carefully remove the cover from the chain brake spring Place one hand over the spring and insert a small screwdriver between the bottom end of the spring and the clutch cover Carefully prise the spring upwards so that it slides onto the screwdriver shaft Cleaning and inspection e 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 Measure the thickness of the chain brake band It must be no less than 0 6 mm at any point e Lubricate the elbow joint with grease Repair instructions Chain brake reassembly Bolt the elbow joint to the brake band 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 2 WARNING Make sure the spring does not fly out and cause injury Wear eye protection Grip the clutch cover in a vice Compress the spring with special tool 502 50 67 01 and push it down with your thumb 3 Fit the cover over the chain brake spring tightening the screws to a torque of 1 1 5 Nm 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 5 Turn the chain tensioner anticlockwise as far as it will go Refit guide bar e chai
47. om and then turn it counterclockwise 1 1 2 turns 3 Press a new L cap on the L needle to the first stop which means that the cap is not fixed to the needle it should rotate independently 4 Adjust the L cap to the richest position turned counterclockwise to stop without turning the needle 5 Let the engine run at C rpm app 1 minute until warm and then let it run on idle Model 2149 W C 12 000 6 Adjust the idle speed to 2 700 rpm 7 Adjust the L needle until the highest possible idling speed is achieved and then run the L needle 1 2 turn counterclockwise Use a narrow blade screw driver w ref no 531 00 48 63 and insert through the hole in the cap max blade width 2 mm 0 08 inch NOTE If the chain rotates turn the idling speed screw T counterclockwise until the chain stops 8 Check that the L cap is still adjusted to its richest position Turned counterclockwise to stop NOTE The L needle must not rotate 9 Gently knock the L cap into position Use a 5 mm 0 2 inch mandrel for ex the locking pin for the bevel gear ref no 502 02 61 03 This is a basic carburettor adjustment Further fine adjustments within the limits the caps allow may be necessary to achieve optimum performance See the Operator s manual English 55
48. rble a little at full throttle without any load The chain must not turn when idling e Ifthe L screw is set too weak this can make the saw difficult to start and cause poor acceleration If the H screw is set too weak the saw will produce less power poor acceleration and there is a risk of engine damage lf either the L or H screws are set too rich it will cause acceleration problems or too low working speed Repair instructions Fuel tank removal WARNING The fuel used in chainsaws is harmful if inhaled may cause skin irritation and is highly flam mable 1 Empty the fuel tank HAY the following e cylinder cover air filter e clutch cover e chain and guide bar starter assembly cable guide 3 Disconnect the fuel hose from the carburettor 4 Disconnect the pushrod from the carburettor by first carefully prising up the spring over the end of the rod where it connects to the throttle lever A Then press the throttle lever forwards B while pressing the throttle pushrod backwards C and lifting it off the lever Withdraw the throttle pushrod from the tank and lift it upwards without pulling it through the rubber inlet manifold Unscrew both stops and the three vibration damp ing springs from the flywheel side and clutch side of the engine 6 Disconnect and remove the fuel hose from the crankcase English 41 Repair instructions Cleaning and inspec
49. ring 504 90 90 02 7 Removal tool Remove seal from clutch side 502 50 55 01 8 Mandrel sealing ring Removing crankshaft 502 54 21 01 9 Cover plate Sealing during pressure testing 502 54 11 02 10 Pressure tester Connection to cylinder 503 84 40 02 11 Feeler gauge Adjusting ignition module 502 51 34 02 12 Clamp stand Clamping the saw 502 51 02 01 13 Clutch tool Centrifugal clutch 502 52 22 02 14 Pressure gauge Pressurisation during testing 502 50 38 01 15 Piston fitting kit Fitting piston 502 50 70 01 16 Test plug Checking ignition module 502 71 13 01 17 Rev counter Adjusting carburettor 502 71 14 01 18 Removal tool Removing crankshaft 502 51 61 01 19 Vacuum gauge Vacuum test 502 50 37 01 20 Assembly pliers Fitting spark plug guard 502 50 06 01 21a Sleeve Fitting crankshaft 502 70 84 01 21b Shaft extension Flywheel side 502 70 45 06 21c Shaft extension Clutch side 502 70 45 07 22 Stop plate Removing crankshaft 502 54 18 01 23 Assembly tool Assembling spring chain brake 502 50 67 01 24 Crankshaft tool Fitting crankshaft seal 502 50 30 16 English 5 Displacement cm3 cubic inches 2149 W 2150 49 4 3 0 2141 40 8 2 5 2145 45 0 2 74 2159 W 59 0 3 6 Spark plug gap mm inches 2149 W 0 5 0 02 2141 2145 2150 0 5 0 02 2159 W 0 5 0 02 Effective cutting length cm inches 2149 W 30 48 12 19 2141 2145 2150 30 43 12 17 2159 W 31 48 12 19
50. ssembly 2 5 3 5 Nm see Starter assembly refitting cylinder cover clutch cover guide bar and chain NOTE lf a new crankshaft has been fitted the saw must be run in for 3 4 hours with the carburettor adjusted to the factory set tings Repair instructions Crankshaft complete 2141 2145 2150 reassembly bagi CS KG Poa i ni the crankshaft complete in the crankcase anga tighten the four bolts holding the spacer from underneath and fit the crankshaft complete in the crankcase Refit the following parts e piston and cylinder e fuel tank silencer e carburettor throttle pushrod centrifugal clutch generator e ignition system starter assembly e cylinder cover e clutch cover e chain and bar See special instructions Repairing damaged threads A repair kit 503 27 39 01 is available for repairing damaged threads First drill out the hole using 6 1 mm drill bit for magnesium crankcase Then screw in the thread insert using a suitable bolt and spanner English 53 Repair instructions Guide bar bolts replacement 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 Fasten a steel wire to the thread of the new bolt feed the steel wire into the oil tank and out through the bolt hole in the crankcase 5 Pull the st
51. tion Carefully check that there are no leaks from the fuel tank there are no leaks from the tank filler cap the fuel hose is undamaged and free from wear e the fuel filter is not clogged e the tank vent is not blocked or leaking the vibration damping springs and stops are not damaged Replacing the fuel filter NOTE Do not use knurled pliers to disconnect or reconnect the fuel hose This could damage the hose and lead to leakage or fracture 1 First remove the old fuel filter from the tank unit using special tool 502 50 83 01 2 Pull the fuel hose out of the tank and pull off the filter 3 Fit the new fuel filter and feed the fuel hose back into position Replacing the fuel hose NOTE Do not use knurled pliers to disconnect or reconnect the fuel hose This could damage the hose 1 Before replacing the fuel hose measure the length of hose between the crankcase and carburettor and between the tank and crankcase The correct hose length between the tank and crankcase is 43 mm 1 69 inches The correct hose length be tween the crankcase and carburettor is 53 mm 2 09 inches 2 Remove the fuel hose from the fuel tank using tool 502 50 83 01 Trim off 5 mm 0 20 inches from the mitred end of the hose Fit the fuel filter and reinsert the hose in the tank 42 English Tank vent testing 1 Connect pressure gauge 502 50 38 01 to the fuel hose Pump the pressure up to 50 kPa
52. tle trigger fuel hose and throttle pushrod to the carburettor check that the hose is not trapped between the tank and crankcase measurement 43 mm 1 69 inches e hand grip cover air filter and cylinder cover Heater element and rear hand grip removal 1 Screw the heater element into place using the two screws and feed the leads through the rear hand grip Secure the red lead in the clip on the tank and connect it Feed the black lead through crankcase and secure earth it to the base of the carburettor using the bolt at the front on the clutch side of the saw Tighten to a torque of 3 4 Nm 2 Refit fuel tank with both stops and the rear vibration damping spring e throttle lock throttle trigger and recoil spring see Throttle trigger fuel hose and throttle pushrod to the carburettor check that the hose is not trapped between the tank and crankcase measurement 43 mm 1 69 inches e hand grip cover air filter and cylinder cover English 19 Repair instructions Hand grip heater on model 2149 2159W refitting 1 Feed the leads into the rear hand grip and insert the heater element in the hand grip Screw in the two bolts through the right side of the hand grip to secure the heater Press the black lead into the base of the carburet tor and connect it with the bolt Tighten to a torque of 3 4 Nm 3 Run the red lead to the front hand grip and connect it 4 Press the thrott
53. ts carefully If there are any cracks or other defects replace the dam aged parts with new ones Always use original parts Models 2141 2145 2149 2150 Min 65mm e Check the thickness of the clutch shoes by using vernier callipers to measure the diameter of the clutch If the diameter is less than 65 mm the clutch assembly must be replaced Repair instructions Model 2159 Min 65 mm Centrifugal clutch refitting 1 Model 2141 2145 2149 2150 NOTE Handle the clutch springs carefully If they are opened up too much they could damage the saw Insert the clutch springs in the shoes using circlip pliers Model 2159 Fit the clutch springs in the shoes using circlip pliers and a screwdriver 2 Models 2141 2145 2149 2150 Fit the clutch onto the crankshaft and tighten anticlockwise as far as it will go Then tighten to a torque of at least 20 Nm using tool 502 54 16 01 and a suitable socket or combination spanner Model 2159 ago PG ft O a Fit the clutch and tighten anticlockwise as far as it will go Then tighten to a torque of at least 20 Nm using tool 502 52 22 02 3 Remove the piston stop Fit the spark plug tightening it to a torque of 15 Nm then connect the HT lead Then refit e cylinder cover guide bar e chain clutch cover English 27 Repair instructions Oil pump removal 2149 2150 2159 1 Empty and clean the oil tank 2
54. w in the idling screw T until the chain starts to turn Then screw it out until the chain stops moving e The idling speed is correctly set when the engine runs smoothly in all positions and there is a clear margin to the speed at which the chain starts to move High speed jet H The high speed jet H influences the saw power output and engine speed If the H jet is set too weak the saw will over rev which could cause engine damage Run the saw at full throttle for about 10 seconds H 1 e Then screw out the H screw 1 4 turn H 1 1 4 e Run the saw again at full throttle for about 10 seconds and listen to the difference in the engine note Repeat this procedure again with the H screw screwed out another 1 4 turn H 1 1 2 You have now run the saw at settings H 0 H 1 4 and H 1 2 from the factory setting At full throttle the engine will sound different at each setting The H screw is correctly adjusted when the saw burbles a little at full throttle without any load If there is a lot of smoke from the silencer and the saw does not run smoothly then the setting is too rich Screw in the H screw to the setting that sounds right NOTE For optimum adjustment a tachometer should be used The recommended maxi mum speed should not be exceeded Carburettor correct adjustment When the carburettor is correctly adjusted the saw should accelerate without hesitation and the engine will bu
55. with new ones Always use original parts Stop switch resistance measurement Clean the mating surfaces and check the resist ance as follows Measure the resistance by connecting a multimeter to the ignition coil NOTE The switch must be in the on position to give the correct reading The resistance must not be higher than 0 2 ohm when the switch is in the on position English 15 Repair instructions Stop switch refitting Carefully press the new stop switch into place Check that the switch s upper mounting clips over the air filter holder Refit the stop plate Engage the stop plate in the front slot first then lift the rear edge onto the stop switch Slide the stop plate in as far as it will go 3 Refit e the leads to the stop plate and stop switch e air filter cylinder 16 English Choke control removal 1 Remove the cylinder cover air filter and stop switch Disconnect the fuel hose from the carburet tor NOTE Do not use knurled pliers to disconnect or reconnect the fuel hose This could damage the hose and lead to leakage or fracture Disconnect the pushrod from the carburettor by first carefully prising up the spring over the end of the rod where it connects to the throttle lever A Then press the throttle lever forwards B while pressing the throttle pushrod backwards C and lifting it off the lever Withdraw the throttle pushrod from the tank and lift
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