High Quality Chainsaw Bars Husqvarna Toys

Husqvarna T540 XP Repair Thread

Onan18

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One of my loggers dropped off a pile of broken 540s and asked me to see what I could do with them. After inspection I told him that I could build two runners with new rings and gaskets. I took pictures of tearing one down to the crankcase for re-ring, if I split a bottom end on one later I will add pictures.

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The Victim.

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Let's begin, remove the air filter cover.

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Air filter is mesh, does a good job.

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Just pulls off, you can see the nylon sponge, catches spit back.

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Strato Saw, two butterflys.
 

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20180124_130654.jpg
Let's get the bar and chain out of the way, single captive bar nut.

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Cover has the chain brake mechanism in it.

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Outboard clutch, pretty standard for climbing saws.
 

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20180124_131039.jpg
Remove the air cleaner base next, two screws through the carb and one small one at the bottom right.

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And off.

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Remove the screw holding the Strato butterfly on.

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Disconnect the wiring for the AutoTune.

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And the purge line.
 

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20180124_132055.jpg
Remove the boot for the air injection.

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Disconnect the pulse line.

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Carb boot has two legs.

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Carefully push them through the airbox.

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And the tank is off, it comes much easier with the spark plug out of the way.
 

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Four screws hold the boot to the cylinder.

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Two here.

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And two here.

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Remove them.

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This A/V mount and the screw behind it also need to come out.

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And the engine shroud pulls off. Be very careful, it is easy to break.
 

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20180124_134813.jpg
Slide the shroud back on.

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Reinstall the screws into the boot flange.

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Also install the screw in the front of the shroud by the chain catcher.

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And the little one that goes into the cylinder.
 

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20180124_141020.jpg
Set the tank back in place.

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Pull the boot through the airbox.

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Reconnect the wires.

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And push them into their retainers.

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Slide the front handle into place and install the screw through the top handle.
 

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20180124_141709.jpg
Reinstall the kill switch.

20180124_141715.jpg Route the wires.

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Grip back on.

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Install the front A/V mount and secure the handle to it.
 

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20180124_143050.jpg
Set the carb back in and reconnect the throttle cable.

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Reconnect the wires and lines.

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Reinstall the Strato butterfly.

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And the air cleaner base.

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Reinstall the plug.
 
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