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254XP Rebuild

Discussion in 'Chainsaws' started by XP_Slinger, Dec 23, 2017.

  1. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Seems like its time for another 2-series rebuild. Here’s where I’m starting from, saved this mostly complete 254 from the junk shelf at my dealer. I’m going to try to give good details like @Onan18 has been in his series of repair threads. I’m no Joe but here we go;
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  2. XP_Slinger

    XP_Slinger I like saws...sometimes

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    3 screws and her top comes off to show you her jug:rolleyes:
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  3. XP_Slinger

    XP_Slinger I like saws...sometimes

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    1 screw releases the air filter, now it’s time to pull the carb...after a little cleaning. Remove the throttle linkage, 2 filter holder screws, 2 carb mount screws then disconnect the fuel line and it comes right out.
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  4. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Looks like I need a new intake partition, added to the list.
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  5. XP_Slinger

    XP_Slinger I like saws...sometimes

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    This coil screw, like many others was packed full of saw dust and bar oil. I pick them clean during disassembly so I don’t round them out. This dental pick does an excellent job but any small pick or screwdriver will do.
    Remove 2 screws and the ignition coil lifts out.
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  6. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Next I removed the clutch using a piston stop. I usually just hold the flywheel and blip the clutch with an impact to remove it but this saw was missing the flywheel. Clutch nut is 15mm reverse thread.
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    Last edited: Dec 23, 2017
  7. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Now that the clutch is off, there arent any more bolts that are tough to break loose so I remove the handle. 2 screws on the side, 2 more on the bottom. The longer screws go on the side With the black spacer.
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    I also took the air injection plastic off at some point. Pretty simple, just 2 screws and it lifts out.
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    Last edited: Dec 23, 2017
  8. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Now it’s time to separate the fuel tank from the crank case. There are only 4 mount screws. 2 are toward the handle up top and the other 2 are near the front of the crank case near the bottom. The fuel line just pulls through the grommet and stays with the tank.
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    Last edited: Dec 23, 2017
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  9. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Now it’s time to clean every piece of the saw. I even clean fasteners while it’s apart, just because.
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  10. XP_Slinger

    XP_Slinger I like saws...sometimes

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    All clean! Don’t let a little grime scare you away from a saw. This little bugger is in really nice shape after getting it cleaned up.
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  11. Mattyo

    Mattyo Youtube speciawist

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    Split it split it split it....hehe
     
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  12. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Next up for removal is the flywheel side seal carrier. 3 fasteners and it comes off to reveal the crank bearing. Note the large oring on the seal carrier. It must be replaced to ensure an air tight seal when reassembling.
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  13. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Patience grasshopper...lol!
     
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  14. Mattyo

    Mattyo Youtube speciawist

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    Also note that bearing is resessed...
     
  15. Mattyo

    Mattyo Youtube speciawist

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    Me wants it now!

    Nice metal holder....those are more desirable than the plastic ones.
     
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  16. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Now to remove the oil pump. 3 fasteners secure the pump body to the crank case. Once removed it will lift right out right? Not so much, I gently pryed on this thing for 20 minutes before making a discovery. These 2 holes are threaded for 5mm bolts. Using cylinder bolts, thread them in until they bottom out on the case, then slowly tighten them and the pump assembly rises out of the grim and into your hand.
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  17. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Next remove the brass pump drive gear. I have heard that a little heat will get it off but I used this puller that my brother @RIDE-RED 350r just happened to have built last week.
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  18. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Remove 4 fasteners and the cylinder is free. Then remove 7 crank case fasteners and don’t forget about the little shite head back by the carb.

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  19. XP_Slinger

    XP_Slinger I like saws...sometimes

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    Now it’s time to split the case.
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  20. Mattyo

    Mattyo Youtube speciawist

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    Those two dog screws messed me up once....didn't know they were case bolts. Tore a case half.....whoops.

    Nice job so far!
     
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