Jonsered CS 2166 Workshop Manual
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Jonsered CS 2166 Workshop Manual

Jonsered CS 2166 Workshop Manual

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CS 2166
CS 2172
CS 2172 WH
Workshop manual
115 49 46-26

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Summary of Contents for Jonsered CS 2166

  • Page 1 CS 2166 CS 2172 CS 2172 WH Workshop manual 115 49 46-26...

  • Page 2: Table Of Contents

    Anti-vibration system ........ 38 Piston and cylinder ........39 Crankcase and crankshaft ....... 43 Trouble shooting ........48 Jonsered AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice.

  • Page 3: Introduction

    Location indicators for components shown in the figures Their use is described in the appropriate section. are marked A, B, etc. The figures are numbered 1, 2 etc. Always use Jonsered original: The location indicators and figure numbers start again from • Spares A, 1 etc.

  • Page 4: Safety Regulations

    SAFETY REGULATIONS Special instructions General instructions The fuel used in the chainsaw poses the following hazards: Workshops where chainsaws are serviced must be equipped with safety equipment in accordance with local 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. regulations.

  • Page 5: Symbols

    SYMBOLS Symbols on the saw Symbols in this manual The markings shown below are moulded into the chainsaw casing. This symbol indicates a risk of personal Choke injury if instructions are not followed. Use protective gloves. Switch for handgrip heating Use protective goggles.

  • Page 6: Technical Data

    TECHNICAL DATA Displacement Bore Stroke Max. power/rpm / cubic inch Ømm/Øinch mm/inches kW/hp/ rpm 365: 70,7/4.3 50/1.97 36/1.42 3,6/4,9 @ 10 200 372XP: 70,7/4.3 50/1.97 36/1.42 4,1/5,6 @ 10 200 372XPG: 70,7/4.3 50/1.97 36/1.42 4,1/5,6 @ 10 200 Sparkplug gap Ignition system Air gap Carburettor type...
  • Page 7 TECHNICAL DATA Idling speed Engagement speed Max. overspeed Spark plug 365: 2 700 3 500 13 300 NGK BPMR7A 372XP: 2 700 3 500 13 300 NGK BPMR7A 372XPG: 2 700 3 500 13 300 NGK BPMR7A Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump...

  • Page 8: Servicetools

    SERVICETOOLS 8 – English...
  • Page 9 SERVICETOOLS Description Used for Order No. Piston stop Locking the crankshaft 504 91 06-05 Cover plate: inlet Sealing off inlet 578 09 56-01 Cover plate: exhaust Sealing off exhaust outlet 502 71 39-01 Pressure tester Pressurising for pressure testing 531 03 06-23 Extractor Removing crankshaft 502 51 61-01...
  • Page 10 SERVICE DATA (x4) 12-14 Nm 5 mm 14-15Nm 16 mm 1,5-2Nm 4 mm 3-4Nm 4 mm 12-14Nm 13 mm 1-2Nm 22-25Nm 13 mm 6-8Nm 4 mm 5-6Nm 4 mm 12-14 Nm 5 mm 8-10 Nm 5 mm 1-2Nm 25Nm Min. 15Nm 13 mm 1-2Nm Key to diagrams Figures next to components which are attached using bolts...
  • Page 11 SERVICE DATA 3,5-4,5 Nm 4mm 3-4 Nm 4mm 2-3 Nm 4mm 2 Nm 4 mm 3-4 Nm 4mm 2 Nm 4 mm 1 Nm 2 Nm 4 mm 1 Nm 2 Nm 4 mm 2 Nm 4 mm 2 Nm 4 mm 2 Nm 4 mm...

  • Page 12: Safety Equipment

    SAFETY EQUIPMENT Chain brake Dismantling 1. First remove the following components: • Chain and guide bar. • Centrifugal clutch. 2. Push the hand guard forward so that the chain brake on. See fig. 1 3. Unscrew hand guard, two bolts. Note sleeving on the Fig.
  • Page 13 SAFETY EQUIPMENT Reassembly Assemble the chain brake as follows: 1. Reattach the toggle joint and brake-strap. See fig. 5. 2. Grease the toggle joint (E) moving parts and locate the assembly in the chainsaw. See fig. 6. 3. Grease and insert the lever arm (D). See fig. 3. min.
  • Page 14 SAFETY EQUIPMENT Chain catcher Remove the chain and guide bar Inspect the chain catcher and replace it if it is damaged. Tighten the retaining bolts to 6 Nm. See fig. 8. Refit chain and guide bar. Silencer Fig. 8 WARNING! Do not touch the silencer before it has cooled.
  • Page 15 SAFETY EQUIPMENT Throttle lock Dismantling 1. Remove the tank unit from the motor unit. WARNING! The fuel that is used in the chainsaw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3.

  • Page 16: Recoil Starter

    RECOIL STARTER Starter Dismantling 1. Undo the four bolts that fasten the starter assembly to the crankcase and remove it. See fig. 1. 2. Pull out the handle 20-30 cm and lift out the cord from the slot in the cord pulley. See fig. 2. 3.
  • Page 17 RECOIL STARTER Reassembly WARNING! Make sure that the recoil spring does not fly up and cause personal injury. 1. If a new recoil spring is to be used, place the new spring, with retaining wire, such that the end loop of the spring is over the peg (A) on the cord pulley.

  • Page 18: Electrical System

    ELECTRICAL SYSTEM Ignition system Dismantling 1. Remove the cylinder cover and starter assembly. 2. Release the blue lead (A) (which connects to the stop switch) from the ignition module (B). See fig. 1. 3. Remove the HT lead (C) from the spark plug, release both leads from the cable guide (D) and lift out the cable guide.
  • Page 19 ELECTRICAL SYSTEM Reassembly Assemble the ignition system as follows: 1. Locate the flywheel on the crankshaft. Turn it gently until the key on the flywheel mates with the recess in the shaft. 2. Fit the flywheel washer and nut. Tighten the nut to 35 Nm.
  • Page 20 ELECTRICAL SYSTEM Hand grip heater Some chainsaws are equipped with hand grip heating. The hand grip heater comprises the following components. • Generator • On/off switch • Heating element in the rear hand grip (tank unit). • Front hand grip with heating element. Trouble shooting Fig.
  • Page 21 ELECTRICAL SYSTEM Replacing the generator 1. Before the generator can be replaced, the following components must be removed: Recoil starter. Flywheel. Silencer. Carburettor. Cylinder. 2. Detach the carburettor space bottom plate by removing the four bolts. See fig. 13. 3. Detach the generator by removing the three fixing bolts.

  • Page 22: Centrifugal Clutch

    CENTRIFUGAL CLUTCH Centrifugal clutch Dismantling During dismantling of the centrifugal clutch, the chain brake must be in the off position. 1. Remove the cylinder cover, chain and guide bar. 2. Remove the chain guide-plate by removing the bolt (A). See fig. 1. 3.
  • Page 23 CENTRIFUGAL CLUTCH Cleaning and inspection Clean all components and check the following: 1. Lining thickness on the clutch shoes should not be min 3 mm less than 3 mm in the most worn area. See fig. 5. In order to avoid imbalance, all clutch shoes should be replaced at the same time.

  • Page 24: Lubrication System

    LUBRICATION SYSTEM Lubrication system WARNING! Inadequate lubrication of the chain can result in the chain breaking which can cause serious or life threatening injury. The lubrication system comprises the following components: • Oil pump • Suction pipe with sieve. Fig. 1 •...
  • Page 25 (E). The table (right) shows the number of turns outward from fully home, required for different lengths of guide bar. -15" The table applies to Jonsered chain oil. If another chain 15"-18" oil is used, the adjuster should be turned one extra turn 18"-24"...

  • Page 26: Carburettor

    CARBURETTOR Carburettor WARNING! The fuel that is used in the chainsaw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Description The diagrams with this description do not show the actual carburettor on the chainsaw.
  • Page 27 CARBURETTOR Function The carburettor operates differently in the following operating states: • Cold start • Idling • Part throttle • Full throttle In cold start mode (fig. 4), the choke butterfly (D) is completely closed. This increase the vacuum in the carburettor so that fuel is sucked more easily from the diffuser jets (E, F and G).
  • Page 28 CARBURETTOR Dismantling WARNING! The fuel that is used in the chainsaw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Removal See fig. 8. 1. Remove the cylinder cover and air filter. 2.
  • Page 29 CARBURETTOR Cleaning and inspection 2. There is no play in the throttle and choke butterflies. WARNING! The fuel that is used in the chainsaw 3. The needle valve and its lever arm are not worn at M poses the following hazards: in fig.
  • Page 30 CARBURETTOR Reassembly 8. Carry out pressure testing. See next page. Assembly Where no figure is referred to, see exploded diagram 12 on the previous page. Complete cleanliness is essential when reassembling the carburettor. The smallest dirt particle can cause running problems.
  • Page 31 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. Refer to fig. 17 and carry out the test as follows: 1.
  • Page 32 CARBURETTOR Adjustment WARNING! The guide bar, chain and clutch cover must be fitted before the saw is star- ted, otherwise the clutch may come loose causing personal injury. WARNING! Wear ear defenders when making ad- justments with the motor running. WARNING! Do not use the saw until it has been adjusted so that the chain is still.
  • Page 33 Due to the integrated speed limitation in the ignition system most tachometers will not indicate a speed above the value that the speed limitation is set to. Speed limitation regulates at: CS 2166 13 300 rpm, CS 2172 13 300 rpm, CS 2172 WH 13 300 rpm.
  • Page 34 (RWJ4) The models CS 2166, CS 2172 and CS 2172 WH are equipped with speed limited ignition systems and carburet- tors with limiters. A slightly different adjustment procedure is necessary when replacing the carburettor or needles on...
  • Page 35 CARBURETTOR Adjustment of the H-needle. 3. While keep pressing the screwdriver, adjust the 1. Turn the H-screw counterclockwise to stop using a H-screw until the maximum engine speed at full throt common, flat carburettor screwdriver. tle is 12 500 rpm. 2.

  • Page 36: Tank Unit

    TANK UNIT Tank unit WARNING! The fuel that is used in the chainsaw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantling 1. Run off the fuel from the tank. 2.
  • Page 37 TANK UNIT Cleaning and inspection Clean all components and check that the fuel line is undamaged. Reassembly 1. If the chainsaw is equipped with hand grip heating, refit the heating element into the rear hand grip, if it has been removed. 2.

  • Page 38: Anti-Vibration System

    ANTI-VIBRATION SYSTEM Anti-vibration system WARNING! The fuel that is used in the chainsaw poses the following hazards: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantling 1. Remove the following components: •...

  • Page 39: Piston And Cylinder

    PISTON AND CYLINDER Piston and cylinder Dismantling 1. Remove the following components: • Cylinder cover. • Spark plug. • Carburettor. • Silencer. 2. Remove the impulse hose (A) from the hole on the inlet manifold. See fig. 1. 3. Detach the anti-vibration springs (B) from the cylinder.
  • Page 40 PISTON AND CYLINDER 2. The cylinder is free of score marks. 3. The piston is free of score marks. Smaller scratches can be polished off with fine emery paper. Max 1 mm 4. The piston ring is not burnt into its groove. 5.
  • Page 41 PISTON AND CYLINDER Reassembly Carry out assembly of the piston and cylinder as follows: NOTE! Ensure that no dirt or other foreign particles fall into the crankcase. Fig. 8 1. Oil in the needle roller bearing and fit it in the connecting rod little end.
  • Page 42 PISTON AND CYLINDER Pressure testing In order to carry out pressure testing on the crankcase and cylinder, the following components should be removed: • Carburettor. • Muffler. Carry out pressure testing as follows: 1. Fit cover plates 578 09 56-01 and 502 71 39-01 to the inlet manifold and exhaust port.

  • Page 43: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT This section deals with the following: • Crankcase and crankshaft (describes how the whole assembly is dismantled and reassembled) • Seals (describes only replacement of seals) • Guide bar bolts (describes only replacement of the guide bar bolts) Crankcase and crankshaft Dismantling 1.
  • Page 44 CRANKCASE AND CRANKSHAFT WARNING! The crankcase halves are hot. Risk for burns. Use protective gloves. Remove the rubber stop (A). See fig. 5. Remove the bush from the chain brake pivot (B). See fig. 6. Remove the oil filler cap. Warm the relevant crankcase half to 200°...
  • Page 45 CRANKCASE AND CRANKSHAFT Reassembly Reassemble the crankcase and crankshaft as follows: WARNING! The crankcase halves are hot. Risk for burns. Use protective gloves. 1. If bearings are to be fitted, proceed as follows: Heat the relevant crankcase half to 200° in an oven.
  • Page 46 CRANKCASE AND CRANKSHAFT 4. Locate the guide pegs in the clutch side crankcase half, grease and locate the gasket. See fig. 12. NOTE! Continuing to pull with the assembly tool after the gasket is clamped will damage the crankshaft. 5. Use tool 502 50 30-14 and pull on the flywheel side crankcase half.
  • Page 47 CRANKCASE AND CRANKSHAFT Crankcase seals 1. To replace the crankcase seals, first remove the following components: On the flywheel side: • Recoil starter. • Flywheel. • Generator if fitted. On the clutch side: • Chain and guide bar. • Chain guide-plate. •...

  • Page 48: Troubleshooting

    TROUBLESHOOTING Troubleshooting The various faults that can affect a chainsaw are divided into four groups. In each group the likely symptoms are given on the left and possible causes are listed on the right. The most likely faults are given first, and so on. Starting Idling (low rpm) (cont.) Difficulty starting...
  • Page 49 TROUBLESHOOTING High rpm Acceleration och retardation Does not Adjust L screw Will not run at Adjust H screw accelerate Adjust H screw full throttle Blocked air filter Blocked air filter Blocked fuel tank vent Blocked fuel tank vent Blocked fuel filter Blocked fuel filter Fuel line blocked Fuel line blocked...
  • Page 50 115 49 46-26 2013W18...

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Cs 2172Cs 2172 wh

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