Husqvarna 592xp woes and fixes

[Stump Shot]

Have a sick stock 592xp in the shop fresh from the woods logging. It barely would start and would not stay running. Sounds like an air leak of some kind.
Decided to look at it physically prior to any more diagnostic testing and after removing the carburetor the culprit became apparent. The first clue was the primer bulb was misaligned in the hole by quite a bit. Second clue was the right side air filter adapter AV was off, allowing the entire setup to lean over. Third and final clue was the tear in the intake boot.

 

[Stump Shot]

The AV on the right is very nimble like a wet noodle compared to its counterpart on the left. These are two different parts with two different ways of attachment. Swapping for a stiffer one isn't an option.

 

[Stump Shot]

So far the only reasonable fix that I can conjure up is to assemble it with a thin safety wire, once the new intake gets here.
If anyone else has any ideas on how else to keep this from repeating I'm all ears.
As this is the second saw down for this logger and this intake is not easy to find and fairly expensive at around $130.00 each

 

[Stump Shot]

Another common failure becoming fairly apparent is the mufflers are self modifying.
The small fastener holding the triangular cover vibrates a hole where it is fastened to the muffler body. The only fix for this is to run it without the cover prior to it self destructing.

 

[Stump Shot]

Back to the intake problem, other than that AV being flimsy, am unsure as to a good reason why the air filter adapter came out of the AV. Also do not quite get just why it is so flimsy compared to the other two. Was it the cold weather that brought this on? It surely had influence on the boot tearing. There are also no winter boots available, like the old 372's used to have as an option for replacement. Also noted was the lack of a summer/winter / for the airbox. The only help you can provide is to install a blue winter kit on the recoil starter.
The one bright side to all of this was the autotune was not able to compensate enough for the saw to keep running and blow up from being too lean. Which, saved even further expense to the owner/operator.

#Husqvarna

 

[singinwoodwackr]

The AV on the right is very nimble like a wet noodle compared to its counterpart on the left. These are two different parts with two different ways of attachment. Swapping for a stiffer one isn't an option.
View attachment 481426

WCS needs to come up with a kit like the 500i.

Could you turn a bushing from a block of rubber?

 

[singinwoodwackr]

Another common failure becoming fairly apparent is the mufflers are self modifying.
The small fastener holding the triangular cover vibrates a hole where it is fastened to the muffler body. The only fix for this is to run it without the cover prior to it self destructing.
View attachment 481427

At least there is a billet AM muffler for these.

 

[MG2186]

Had to replace my intake for the same reason. It was below zero when it happened. I couldn’t find any clear reason for it to happen. It seems the front of these mufflers are all beat to crap when they are breaking a part. With standard dogs this is inevitable

 

[singinwoodwackr]

@Loggernate , how is yours holding up?

 

[Stump Shot]

WCS needs to come up with a kit like the 500i.

Could you turn a bushing from a block of rubber?

Personally, I think it's something Husqvarna should be looking to fix.

It's not a fitting issue, it's a matter of it staying in where it belongs issue.

At least there is a billet AM muffler for these.

This particular set of 592's are not having the exhaust replaced/repaired per the owner/operator's request.

Had to replace my intake for the same reason. It was below zero when it happened. I couldn’t find any clear reason for it to happen. It seems the front of these mufflers are all beat to crap when they are breaking a part. With standard dogs this is inevitable

These two saws also were in operation in below zero temps. Seems to be a pattern here....
Some fairly new and still pristine versions have also done the same self-mod. This particular 592xp was of the very first to come out and has been in pro service ever since, so I would expect a bit of abuse after a number of years as compared to every other saw out there doing the same type of work.

 

[MG2186]

Personally, I think it's something Husqvarna should be looking to fix.

It's not a fitting issue, it's a matter of it staying in where it belongs issue.


This particular set of 592's are not having the exhaust replaced/repaired per the owner/operator's request.


These two saws also were in operation in below zero temps. Seems to be a pattern here....
Some fairly new and still pristine versions have also done the same self-mod. This particular 592xp was of the very first to come out and has been in pro service ever since, so I would expect a bit of abuse after a number of years as compared to every other saw out there doing the same type of work.

If you leave that cover off do the mufflers still self modify? I noticed when putting my pipes in them they seem to crack very easily

 

[MG2186]

I also wasn’t very impressed with the price and availability of the intake

 

[Colonel 428]

For some reason I thought Husqvarna started putting a newer, beffier muffler on the more recent 592xps. I got a new one from Bruce at HL Supply a year or so ago and it seemed (and felt) a little heavier than than the one that came on it. Probably a 5 year old saw for what it's worth.

 

[Stump Shot]

If you leave that cover off do the mufflers still self modify? I noticed when putting my pipes in them they seem to crack very easily

Allegedly no, but in practice??? I haven't one to try it out on that's still whole.

For some reason I thought Husqvarna started putting a newer, beffier muffler on the more recent 592xps. I got a new one from Bruce at HL Supply a year or so ago and it seemed (and felt) a little heavier than than the one that came on it. Probably a 5 year old saw for what it's worth.

This is also an old saw, one of the first to come out.

 

[MG2186]

Allegedly no, but in practice??? I haven't one to try it out on that's still whole.


This is also an old saw, one of the first to come out.

I would agree with this, the last one I did was a little thicker

 

[jacob j.]

Another common failure becoming fairly apparent is the mufflers are self modifying.
The small fastener holding the triangular cover vibrates a hole where it is fastened to the muffler body. The only fix for this is to run it without the cover prior to it self destructing.
View attachment 481427

The same thing happened on the 385/390. Mufflers were rattling apart and Husqvarna had to make a MKII muffler for the 385/390. The flange would crack where the body of the muffler bolted to the cylinder and then it would flop around and become scrap. They also had a run of mufflers for the early 2100s that didn't hold up either.

 

[EFSM]

The AV on the right is very nimble like a wet noodle compared to its counterpart on the left. These are two different parts with two different ways of attachment. Swapping for a stiffer one isn't an option.
View attachment 481426

I’d guess that the “wet noodle” had a fuel leak onto it that caused that. The old 028’s would leak fuel from the vent up onto the anti-vibe bushing and turn it into a spongy mess. Has this saw had a known fuel leak?

 

[Stump Shot]

I’d guess that the “wet noodle” had a fuel leak onto it that caused that. The old 028’s would leak fuel from the vent up onto the anti-vibe bushing and turn it into a spongy mess. Has this saw had a known fuel leak?

No, this is the first service they've seen. The left noodly one is part number 597909701, the stiffer one on the right is part number 595013901.

 

[Maintenance Chief]

I thought the case reinforcement was added after the first run of 592xp's came out? Because of the spike breaking that corner off.
I could be wrong or the case side could have been replaced?

 

[Stump Shot]

The same thing happened on the 385/390. Mufflers were rattling apart and Husqvarna had to make a MKII muffler for the 385/390. The flange would crack where the body of the muffler bolted to the cylinder and then it would flop around and become scrap. They also had a run of mufflers for the early 2100s that didn't hold up either.

You're old. Lol