Chain saws - Jonsered CS 2141 S
http://www.tilton.usa.jonsered.com/node326.aspx?pid=6775
The Jonsered 2100 chainsaws in the 40-50 cc class are set to become firm favourites with demanding part-time professionals, forest owners and hobby users. This model is perfect for users who need a small saw for cutting firewood and occasionally working in the forest. It has the slim engine housing and convenient design characteristic of the 2100 generation. It also has Spin Start and air purge for easier starting, turbo air cleaning, highly efficient vibration damping and quick-release air filter.
Cylinder displacement Power Fuel tank volume Oil tank volume Oil pump type Power to weight ratio Chain pitch Recommended bar length Sound level Noise emissions, LWA Vibrations, front/rear handle Weight excl. cutting equipment
2.5 cu.inch / 40.8 cm 2.7 hp / 2.0 kW 1.06 US pint / 0.50l 0.52 US pint / 0.25l fixed flow 0.41 kW/kg / 0.19 kW/lbs.325" 13-18" / 33-45 cm 101 dB(A) 113 dB(A) 3.2 m/s / 4.0 m/s 11.0 lbs / 5.0 kg
Turbo air filtration Air purge primer Coil spring anti-vibration system Side-mounted chain tensioner Combined choke/start control

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Chain pitch mm/inches 8,25 / 0,325" 8,25 / 0,325" 8,25 / 0,325" 8,25 / 0,325" 8,25 / 0,325" 9,52 / 3/8" 8,25 / 0,325" 9,52 / 3/8"
Drive link mm/inches 1,3 / 0,050" - 1,5 / 0,058" 1,3 / 0,050" - 1,5 / 0,058" 1,3 / 0,050" - 1,5 / 0,058" 1,3 / 0,050" - 1,5 / 0,058" 1,5 / 0,058" 1,5 / 0,058"
Idling speed rpm CS 2149/W: CS 2141/CS 2145/ CS 2150: CS 2147/C/W/H: CS 2152/C/W/H: CS 2156/C/W/H: CS 2159/C/W/H: Engagement speed rpm Max. speed rpm / / Spark plug NGK BPMR 7A, Champion RCJ 7Y NGK BPMR 7A, Champion RCJ 7Y NGK BPMR 7A, Champion RCJ 7Y NGK BPMR 7A, Champion RCJ 7Y NGK BPMR 7A, Champion RCJ 7Y NGK BPMR 7A, Champion RCJ 7Y
Fuel tank capacity Litres/US pints CS 2149/W: 0,5 / 1,06 CS 2141/CS 2145/ CS 2150: 0,5 / 1,06 CS 2147/C/W/H: 0,5 / 1,06 CS 2152/C/W/H: 0,5 / 1,06 CS 2156/C/W/H: 0,68 / 1,43 CS 2159/C/W/H: 0,68 / 1,43
Oil pump capacity at 9,000 rpm, ml/min 5 - / 9 / 5-- - - - 17
Oil tank capacity Litres/US pints 0,28 / 0,59 0,25 / 0,53 0,28 / 0,59 0,28 / 0,59 0,38 / 0,80 0,38/ 0,80

Automatic oil pump

Yes Yes Yes Yes Yes Yes
Weight without bar and chain kg / lbs CS 2149: 4,9 / 10,8 CS 2149 W: 5,0 / 11,0 CS 2141/CS 2145/ CS 2150: 4,9 / 10,8 CS 2147/C: 5,0 / 11,0 CS 2147 WH/CWH: 5,1 / 11,2 CS 2152/C: 5,0 / 11,0 CS 2152 W/WH/ CW/CWH: 5,1 / 11,2 CS 2156/W/H: 5,6 / 12,4 CS 2156 C/CWH: 5,7 / 12,6 CS 2159/C: 5,6 / 12,4 CS 2159 W/H: 5,7 / 12,6
Weight with bar and chain kg / lbs 5,7 / 12,4 5,8 / 12,4 5,7 / 12,4 5,8 / 12,6 5,9 / 13,0 5,8 / 12,6 5,9 / 13,0 6,4 / 14,1 6,5 / 14,3 6,4 / 14,1 6,5 / 14,3
Heated hand grips Yes Yes Yes Yes Yes Yes Yes

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Carburettor
The carburettor consists of three sub-systems: The carburettor works in different ways depending on the setting: Cold start mode Idling mode Part throttle mode Full throttle mode
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 ammable mixture.
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).
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.
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).

Too much fuel at idling

Idling too rich

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Troubleshooting High rpm Will not run at Adjust H screw full throttle Blocked air lter Blocked fuel tank vent Blocked fuel lter 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 Metering system damaged Metering system incorrectly assembled Leaking control diaphragm/cover plate Needle valve assembly sticking Blocked silencer Low power Adjust H screw Blocked fuel tank vent Blocked fuel lter Impulse channel leaking Impulse channel blocked Loose cover on carburettor pump side Faulty pump diaphragm Blocked air lter 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 lter 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 Acceleration and retardation Does not accelerate Adjust L screw Adjust H screw Blocked air lter Blocked fuel tank vent Blocked fuel lter 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 Needle 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 Adjust L screw Adjust H screw Blocked air lter Faulty pump diaphragm Faulty diffuser jets
Engine stalls when throttle released

Over rich acceleration

Troubleshooting methods
In addition to the faults described in the above table, trouble shooting can be carried out on specic components or sub-systems of the chainsaw. The various procedures are described in the relevant chapters, see the contents page, as follows: Checking the operation of the chain brake Measuring the resistance of the stop plate Pressure testing the carburettor Pressure testing the decompression valve Pressure testing the cylinder

Will not fourstroke

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Chain brake dismantling

WARNING! Make sure the spring does not y out and cause injury. Wear eye protection.
Disengage the brake by pushing the kickback guard backwards. Unscrew the guide bar bolts and remove the clutch cover, chain and guide bar. 2

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 lter holder.

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Choke control retting
First reattach the choke control to the air lter, then press it onto the carburettor so that the clips engage. Then ret: stop switch carburettor into its rubber mountings throttle pushrod into the fuel tank and connect to throttle lever. lift the spring arm over the throttle pushrod fuel hose to the carburettor air lter and cylinder cover
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. Lubricate the throttle lock with oil. Check that the spring is not broken and has not lost its tension.
Throttle lock, throttle trigger and return spring retting
Throttle lock, throttle trigger and return spring removal
Ret 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.
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). 2
Drive out the steel pin using a 2.5 mm/0.1" diameter drift (A). Push it out from the ywheel side of the saw. Remove the throttle trigger by rst pressing it towards the clutch side of the saw (B) until it clicks, then towards the ywheel side until it clicks again. Remove it from the tank and lift out the return spring.
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 positions when released.

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Hand grip heater on model CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W removal
No heating or heating only in front hand grip Front hand grip troubleshooting 1
2 Reconnect the lead and ret the hand grip cover and cylinder cover. 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 0 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 lter and cover from the rear hand grip.

0,3 mm

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Repair instructions 3

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
Then ret: cable guide and press the leads into position HT lead starter assembly, tighten to a torque of 2.53.5 Nm cylinder cover Disconnect the HT lead. Remove the spark plug and t piston stop 15-01 in its place. 3 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152
Unbolt the clutch using tool 16-02 and a suitable socket or combination spanner. Turn the nut clockwise to remove it. Model CS 2156, CS 2159
Use clutch tool 22-English
Repair instructions 4 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152 NOTE! Handle the clutch springs carefully. If they are opened up too much they could damage the saw. Model CS 2156, CS 2159

Min 65 mm

Centrifugal clutch retting
1 Model CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152 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 screwdriver. Model CS 2156, CS 2159

Inspection and cleaning

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. Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152 Insert the clutch springs in the shoes using circlip pliers. Model CS 2156, CS 2159

Min 65mm

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. Fit the clutch springs in the shoes using circlip pliers and a screwdriver.

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Repair instructions 2 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152
Oil pump removal CS 2147, CS 2149, CS 2150, CS 2152, CS 2156, CS 2159
1 Empty and clean the oil tank. 2

The item numbers in the diagram refer to the steps below (18).
Repair instructions 1 If the throttle and choke butteries and their spindles were removed, these must be retted. Lubricate the spindle bearings with light oil. 2 Insert the plug in the hole with the convex side upwards and expand it by pressing downwards with a drift. 3 Ret 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 lter, using the handle of a small screwdriver. 5 Fit the pump diaphragm, gasket and cover to the pump unit. 6
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 troubleshooting before dismantling. Carry out the test as follows: Screw in the high and low speed jet screws and back them off one turn. Connect pressure tester 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.
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 ret the cover to the metering unit. 8 Carry out pressure testing.
Leakage Diffuser jets In impulse tube Ventilation hole above metering unit
Fault lies in Needle valve Pump diaphragm Control diaphragm

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Carburettor retting
NOTE! Cleanliness is very important when reassembling the carburettor. Tiny particles of dirt can cause operating problems. 1
Fit the carburettor. Screw in the carburettor bolts directly from behind, without lifting the carburettor assembly. Tighten to a torque of 11.5 Nm. It is important to hold the carburettor ange while tightening the bolts to prevent the inlet manifold from moving. 3 Fit stop plate 17-01 between the carburettor ange and the insulating plate.
On saws with a carburettor heater CS 2147 H, CS 2149 H, CS 2152 H, CS 2156 H, CS 2159 H
Push the rear carburettor mounting into its rubber bushing using a small screwdriver. Remove stop plate 17-01. 4

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Basic requirements Before making any adjustments the air lter should be clean and the cylinder cover should be in place. If the carburettor is adjusted with a dirty air lter, the mixture will be too weak next time the air lter is cleaned. This can cause serious engine damage. Carefully screw in the L and H jets fully, then back them off 1 turn. The carburettor now has the settings H = 1 and L = 1. Start the chainsaw and allow it to warm up for 10 minutes. Place the saw on a at 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 Find the highest idling speed by slowly screwing the L screw in and then out again. When the highest speed has been found, screw out the L screw 1/8 - 1/4 turn.

Fuel tank removal

WARNING! The fuel used in chainsaws is harmful if inhaled, may cause skin irritation and is highly ammable. 1 Empty the fuel tank. 2 Remove the following: cylinder cover air lter clutch cover chain and guide bar starter assembly cable guide 3 Disconnect the fuel hose from the carburettor. 4
Unscrew both stops and the three vibration damping springs from the ywheel side and clutch side of the engine. 6
Disconnect the pushrod from the carburettor by rst 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.
Disconnect and remove the fuel hose from the crankcase.

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Carefully check that: there are no leaks from the fuel tank there are no leaks from the tank ller cap the fuel hose is undamaged and free from wear the fuel lter is not clogged the tank vent is not blocked or leaking the vibration damping springs and stops are not damaged

Tank vent testing

Replacing the fuel lter
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 lter from the tank unit using special tool 83-01. 2 Pull the fuel hose out of the tank and pull off the lter. 3 Fit the new fuel lter and feed the fuel hose back into position.

Connect pressure gauge 38-01 to the fuel hose. Pump the pressure up to 50 kPa (0.5 bar). The pressure should drop to 20 kPa (0.2 bar) within 60 seconds. 2

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 between the crankcase and carburettor is 53 mm (2.09 inches). 2 Remove the fuel hose from the fuel tank using tool 83-01. Trim off 5 mm (0.20 inches) from the mitred end of the hose. Fit the fuel lter and reinsert the hose in the tank.
Use gauge 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 retting

1 Insert the fuel hose into the carburettor chamber. Ret the fuel tank. 2
Bolt the front vibration damping spring into position, followed by both stops and the remaining two vibration damping springs. Tighten to a torque of 23 Nm. Check that both vibration damping springs and the stops are correctly seated on the crankcase. Incorrect tting may result in higher vibration levels.

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Piston and cylinder removal
1 Remove: cylinder cover carburettor (see Carburettor removal) silencer spark plug fuel tank (applies to CS 2141, CS 2145)
Fit the throttle pushrod in the tank and connect it to the carburettor. Ret the spring. 4
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 crankcase 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
Unbolt the vibration damping spring from the hand grip. 3
Undo the four cylinder bolts and lift the cylinder off carefully. Models CS 2141, CS 2145
Connect the fuel hose to the carburettor. 6 Then ret: cable guide starter assembly (2.53 Nm) chain and guide bar clutch cover air lter cylinder cover 46 English
Undo the four cylinder bolts from the underside and lift the cylinder off carefully.
Repair instructions 4 Cover the opening in the crankcase. 5 8
When replacing the cylinder CS 2141, CS 2145: Unscrew the decompression valve. (CS 2145) Remove the intake system, see Air intake system removal. Remove the circlips from the ends of the gudgeon pin and press it out. Then lift off the piston. 6 Model CS 2150 is tted with a spacer, which is secured using four bolts from the underside. The spacer does not however need to be removed when removing the cylinder.

Remove the bearing from the little end of the connecting rod. 7 Clean all the components, scraping off all traces of old gasket and carbon from the following places: Piston crown Top of the cylinder bore Cylinder exhaust port Decompression valve channel (CS 2145, CS 2149, CS 2150, CS 2152) Cylinder base and/or crankcase Check the following: The surface coating of the cylinder is not worn through, especially in the upper part of the cylinder. If replacing the cylinder: Unscrew the decompression valve. Remove the intake system, see Air intake system removal. The cylinder is free from score marks and areas of wear. The piston is free from score marks. Small scratches can be polished out with ne emery paper. The piston ring is not burnt into its groove.

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Piston and cylinder retting CS 2147, CS 2149, CS 2150, CS 2152, CS 2156, CS 2159
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. Pressure test the decompression valve. Also refer to Jonsereds Analysis guide for piston failures, art. no. 01-01. Lubricate the little end bearing with two-stroke oil and insert it in the connecting rod. 2
Decompression valve pressure testing
Connect tool 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).
Fit the piston with the arrow pointing towards the exhaust port. Push in the gudgeon pin and t the circlips. If replacing the cylinder, t the decompression valve, tightening to a torque of 1214 Nm.

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Repair instructions 3 6
Fit the inlet manifold 63-01 to the cylinder. Check that the impulse tube is correctly seated in the impulse channel. NOTE! It is very important that there are no leaks in the inlet system, otherwise the engine may seize. 4 Fit a new cylinder base gasket. Compress the piston ring with tool 70-01 and lower the cylinder over it carefully. 7
Press the insulating plate 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.
Fit the cylinder bolts, tightening them in diagonal pairs to a torque of 810 Nm.

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Piston and cylinder retting CS 2141, CS 2145, CS 2152, CS 2159
1-5 See Piston and cylinder CS 2147, CS 2149, CS 2150, CS 2152, CS 2156, CS 2159 Retting points 1-5. 6 Apply silicone adhesive/sealing compound (037062) to the crankcases 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 retted in the crankcase. 7

Cylinder pressure testing
Loosen the carburettor bolts so that the carburettor can be moved back about 4 mm. Insert cover plate 11-02 between the carburettor and the carburettor ange. Tighten the carburettor bolts to a torque of 11.5 Nm. Loosen the silencer bolts so that the silencer can be moved back about 4 mm. Insert cover plate 11-02 between the silencer and the exhaust ange on the cylinder ange. Tighten the silencer bolts to a torque of 810 Nm. Unscrew and remove the spark plug. Screw in pressure test nipple 40-02. Connect tool 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 pressure 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 specied torque. Remove the pressure test nipple 40-02 and ret the spark plug. WARNING! After pressure testing the cylinder, check that the inlet manifold is seated correctly, otherwise the saw may be damaged.
Fit the cylinder bolts, tightening crosswise to a torque of 1315 Nm. 8 Pressure test the cylinder. 9 Ret: spark plug, tighten to a torque of 15 Nm carburettor, see Carburettor retting, silencer, tighten to a torque of 810 Nm cylinder cover
NOTE! If a new piston or cylinder has been tted the saw must be run for the rst 34 hours with carburettor adjusted to the factory settings.

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Crankcase and crankshaft dismantling CS 2147, CS 2149, CS 2152, CS 2156, CS 2159
1 Remove the following: guide bar and chain clutch cover cylinder cover starter assembly* ignition system* generator* centrifugal clutch* oil pump* bark rest chain tensioner throttle pushrod carburettor* carburettor base silencer* piston and cylinder* fuel tank* * See special instructions. NOTE! Take care to prevent dirt or foreign particles getting into the bearings. 2
Split the crankcase with the aid of tool 6101 (A) and stop plate 18-01 (B), working from the ywheel side of the saw. 4
Press the crankshaft out of the ywheel side of the crankcase using tool 61-01. 5 Do the same on the clutch side without using stop plate 18-01.
Unscrew the 6 bolts that hold the crankcase together.

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Crankshaft complete - dismantling CS 2141, CS 2145, CS 2150
1 Remove the following: chain and bar clutch cover cylinder cover starter assembly* ignition system* generator centrifugal clutch* throttle pushrod carburettor* silencer* piston and cylinder* fuel tank* * See special instructions. 2
Crankshaft bearings replacement CS 2147, CS 2149, CS 2152

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Repair instructions 2 fuel tank* piston and cylinder* generator* carburettor base carburettor* throttle pushrod silencer* Check that the guide pins are in place. Fit a new gasket to the mating surface of the clutch side of the crankcase. 3 ignition system* starter assembly* cylinder cover clutch cover guide bar and chain * See special instructions. NOTE! If a new crankshaft has been tted the saw must be run in for 3-4 hours with the carburettor adjusted to the factory settings.
Crankcase and crankshaft reassembly CS 2156, CS 2159
Place the ywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 30-18. 4
Hold the clutch side of the crankcase in a vice. Pull the crankshaft into its bearing using assembly tools 30-16. 2 Fit and tighten the six crankcase bolts to a torque of 810 Nm. Check that the crankshaft rotates freely. 5 Ret the following parts: bark rest oil pump* chain tensioner centrifugal clutch* 54 English Check that the guide pins are in place. Fit a new gasket to the mating surface of the clutch side of the crankcase.
Repair instructions 3 ignition system, 8-10 Nm, see Ignition module and ywheel - retting starter assembly, 2,5-3,5 Nm, see Starter assembly - retting cylinder cover clutch cover guide bar and chain NOTE! If a new crankshaft has been tted the saw must be run in for 3-4 hours with the carburettor adjusted to the factory settings.
Crankshaft complete CS 2141, CS 2145, CS 2150 reassembly
Place the ywheel side of the crankcase over the crankshaft and pull the two crankcase halves together using assembly tools 30-16. 4
1 Fit the crankshaft complete in the crankcase. Fit and tighten the six crankcase bolts to a torque of 810 Nm. Check that the crankshaft rotates freely. 5 Ret the following parts: bark rest, 8-10 Nm oil pump, 3-4 Nm, see Oil pump - retting chain tensioner centrifugal clutch, min 20 Nm, see Centrifugal clutch - retting fuel tank, see Fuel tank - retting piston and cylinder, see Piston and cylinder - retting generator, see Replacing the generator carburettor base, 3-4 Nm carburettor, 1-1,5 Nm, see Carburettor - retting throttle pushrod silencer, 12-14 Nm, see Silencer - retting CS 2150: Fit and tighten the four bolts holding the spacer from underneath and t the crankshaft complete in the crankcase. Ret the following parts: piston and cylinder* fuel tank* silencer* carburettor* throttle pushrod centrifugal clutch* generator* ignition system* starter assembly* cylinder cover clutch cover chain and bar * See special instructions.

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Repairing damaged threads
A repair kit, 33-01, 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.
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. 4

Thread insert

A damaged thread can be repaired using a thread insert. The slotted part of the thread insert is screwed in rst, as this is the cutting part. To repair a thread that was originally designed for a PL5 screw: rst drill out with a 6.1 mm diameter drill bit, then screw in the thread insert using a suitable screw and spanner. To repair a thread that was originally designed for a MT6 screw: rst drill out with a 7.1 mm diameter drill bit, then screw in the thread insert using a suitable screw and spanner. This type of thread insert is best suited for use in plastic and magnesium, but not for repairing threads in aluminium. In that case use a helicoil insert with metric screw. New part no. 39-27 40-01 Description PL5 MT6 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 steel 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 Rell with chain oil.

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Appendix A

Carburetors - EPA-models

Basic adjustment for EPA II carburetors valid from January 2002 After replacing the carburetor or high speed and/or low speed needle on an EPA (The US Environmental Protection Agency) certied 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 instruction is made for USA & Canada only. On EPA carburetors both the H- and L-needles are tted with caps to prevent the chain saw operator from changing the adjustment above EPA standard. The caps can be removed to achieve richer or leaner adjustments. To set the needles correctly an adjustment sleeve is tted from the factory over the caps to lock them in maximum allowed settings. When correctly set the caps must be xed on the needles. The adjustment sleeve then can be removed. NOTE! Before making any adjustments the following must be done! Mount, for this model, approved bar & chain combination (See Technical data in the Operators manual). Model CS 2141/CS 2145/CS 2150 Model CS 2149/CS 2152 Model CS 2147/CS 2156/CS 2159 15" 15" 16" 5. Let the engine run at B rpm ~ 1 minute, until warm. 6. Adjust the H-needle to a top speed of C rpm. Model CS 2141/CS 2145/CS 2150 Model CS 2149/CS 2152 Model CS 2156 Model CS 2147 Model CS 2159 C = C = C = C = C = 14 000

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. 61-03). This is a basic carburetor adjustment. Further ne adjustments, within the limits the caps allow, may be necessary to achieve optimum performance. See the Operators manual. Replacement of the L-needle 1. Take off the cap from the L-needle using e.g. a pair of cutting pliers and unscrew the needle. 2. Screw the new L-needle to the bottom and then turn it counterclockwise 1 1/2 turns. 3. Press a new L-cap on the L-needle to the rst stop, which means that the cap is not xed 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 ~ E app.1 minute until warm and then let it run on idle. Model CS 2141/CS 2145/CS 2150 Model CS 2149/CS 2152 Model CS 2159 Model CS 2147 Model CS 2156 6. Adjust the idle speed to rpm. 7. Adjust the L- needle until the highest possible idling speed is achieved and then turn the L-needle 1/2 turn counterclockwise. Use a narrow blade screwdriver w. ref.no. 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. 61-03). This is a basic carburetor adjustment. Further ne adjustments, within the limits the caps allow, may be necessary to achieve optimum performance. See the Operators manual.

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The chain should not be tensioned more than that it remains ~0,2 inches to the bar. Mount a new air lter. Replacement of the H-needle or complete carburetor 1. Screw the new H-needle to the bottom and turn it counterclockwise A turns. Model CS 2141/CS 2145/CS 2150 Model CS 2149/CS 2152 Model CS 2147/CS 2156/CS 2159 A = 3/4 A = 3/4 A = 3/4
E = E = E = E = E = 13 500
2. Check that: The H-cap is adjusted to its richest setting. (Turned counterclockwise to stop.). The cap is not xed 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 B rpm. Model CS 2141/CS 2145/CS 2150 Model CS 2149/CS 2152 Model CS 2159 Model CS 2147 Model CS 2156 B = B = B = B = B = 13 500

Use a narrow blade screwdriver (Ref.no. 48-63) and insert it through the hole in the cap (max. blade width 2 mm/0.08 inch).

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