Chain saws - Jonsered CS 2156 C
http://www.tilton.usa.jonsered.com/node326.aspx?pid=20
The rapid acceleration 56.5 cc engine and excellent balance make this saw perfectly suited for logging where there is a lot of limbing work. High power, low weight and excellent balance in a compact and streamlined housing make it both extremely easy to handle and effective. As you would expect, the saw has all the advantages of the 2100 generation such as turbo air cleaning, anti-vibration carburettor, side-mounted chain tensioner, decompression valve and quick-release cylinder cover. The saw also has a special low temperature catalytic converter.
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
3.45 cu.inch / 56.5 cm 4.4 hp / 3.2 kW 1.43 US pint / 0.68l 0.80 US pint / 0.38l Adjustable flow 0.57 kW/kg.325 3/8" 13-20" / 33-50 cm 102 dB(A) 114 dB(A) 3.2 m/s / 3,9 m/s 12.3 lbs / 5.6 kg
Turbo air filtration Coil spring anti-vibration system Side-mounted chain tensioner Adjustable oil pump for chain lubrication Quick-release cylinder cover Combined choke/start control Automatic fuel compensation Compression-release valve Catalytic converter muffler

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10/4/2008 1:40 PM

Workshop manual

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Jonsered CS 2141 / CS 2145 / CS 2147/C/W/H / CS 2149/C/W/H / CS 2150 / CS 2152/C/W/H / CS 2156/C/W/H / CS 2159/C/W/H

Contents

Introduction... 2 Safety regulations.. 3 General instructions.. 3 Special instructions.. 3 Special tools.. 4 Technical data.. 6 Construction and function.. 8 Carburettor.. 8 Troubleshooting.. 10 Repair instructions.. 12 Chain brake.. 12 Silencer.. 14 Chain catcher... 14 Stop switch.. 15 Stop switch resistance measurement. 15 Choke control... 16 Throttle trigger.. 17 Hand grip heater.. 18 Starter assembly... 20 Starter cord.. 21 Recoil spring... 21 Ignition module testing.. 22 Ignition module and ywheel.. 23 Generator.. 24 Centrifugal clutch... 26 Oil pump... 28 Carburettor.. 32 Carburettor pressure testing. 34 Carburettor heater.. 36 Air intake system.. 37 Carburettor adjustment.. 39 Fuel tank... 41 Fuel lter... 42 Fuel hose... 42 Piston and cylinder.. 43 Decompression valve pressure testing. 45 Cylinder pressure testing. 47 Crankcase and crankshaft.. 48 Crankshaft bearings... 49 Repairing damaged threads.. 53 Guide bar bolts.. 54 Appendix A, Carburettor EPA models. 55

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Introduction
Arrangement of the manual
This workshop manual can be used in two different ways. To repair a specic sub-assembly on a chainsaw. To dismantle and reassemble a complete chainsaw. Repairing a specic sub-assembly If a specic sub-assembly on the chainsaw needs to be repaired: 1. Look up the page referring to the relevant subassembly. 2. Follow the instructions under the headings: Removal/Dismantling Cleaning and inspection Retting/Reassembly Dismantling and reassembling the entire chainsaw If the entire chainsaw is to be dismantled, follow the instructions under the heading Removal/Dismantling. Work through the manual and follow the instructions given in each section under the heading Removal/Dismantling. Then follow all the Cleaning and inspection instructions in each section. Working from the back of the manual, follow all the instructions under the headings Retting/Reassembly in reverse order. Each of the sections covering removal/dismantling and retting/reassembly include the relevant lubrication instructions and bolt torques for each stage of repair.

Troubleshooting

These pages describe the most common faults that affect a chainsaw. They are divided into four different groups with the most likely faults described rst.

Repair instructions

The section that describes how to repair the chainsaw consists of detailed, step-by-step instructions. It explains in detail the special tools, lubricants and bolt torques that are needed when working on each component.
This workshop manual covers the following chainsaw models: CS 2141 CS 2145 CS 2147 CS 2147 C CS 2147 WH CS 2147 CWH CS 2149 CS 2149 WH CS 2150 CS 2152 CS 2152 C CS 2152 WH CS 2152 CWH CS 2156 CS 2156 C CS 2156 WH CS 2156 CWH CS 2159 CS 2159 C CS 2159 WH CS 2159 CWH
Construction and function
This chapter gives a simple description of the chainsaw carburettor and its various parts.

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Safety regulations

General instructions

This workshop manual gives detailed instructions on how to troubleshoot, repair and test a chainsaw. This section also describes the various safety precautions that should be taken when carrying out repairs. The workshop manual has been written for personnel who are assumed to have general experience of repairing and servicing chainsaws. Workshops where chainsaws are repaired must be equipped with safety equipment that meets local regulations. No-one should carry out repairs on a chainsaw until they have read and understood the contents of this workshop manual. Chainsaws are type-approved to meet the relevant safety legislation, but this only applies when the saw is tted with the cutting equipment specied in the users manual. The tting of any other equipment, or of accessories or parts that are not approved by Jonsered, could mean that the saw no longer meets these safety requirements and the person who carried out the work may be held responsible for its non-conformance. In this workshop manual the following boxes indicate where caution should be taken.

Special instructions

The fuel that is used in a chainsaw poses the following hazards: The fuel and its fumes are toxic. May cause irritation to skin or eyes. May cause breathing difculties. Highly ammable. When using compressed air the air jet should never be pointed at the body. Air can be forced into the bloodstream and cause fatal injury. Wear ear protection when testing saws. After testing a saw do not touch the silencer until it has cooled down. The silencer gets very hot and you may burn yourself. Wear protective gloves when working on the silencer. The guide bar, chain and clutch cover (chain brake) must be tted before the saw is started. If not, the clutch may come loose and cause injury. Poor chain lubrication can result in failure of the chain, which could cause serious or fatal injury. Take care to ensure that the spring inside the starter assembly does not y out and cause injury. Wear eye protection. If the spring is under compression when the pulley is removed it could y out and cause injury. Before removing the tensioning spring from the chain brake, ensure that the brake is in the on position, otherwise the spring may y out and cause injury. After completing the repair the chain brake must be tested, see Chain brake reassembly \ Operating test. Always consider the re risk. A chainsaw can produce sparks that could start a re. Inspect the chain catcher and replace it if it is damaged.
WARNING! The warning text warns of the risk of personal injury if the instructions are not followed.
NOTE! The warning text warns of the risk of material damage if the instructions are not followed.

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Special tools

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21 b 21 c Item Description Clutch tool Piston stop Stop plate Fuel lter hook Allen key Puller Removal tool Cover plate Pressure tester Feeler gauge Clamp stand Clutch tool Pressure gauge Piston tting kit Test plug Rev counter Removal tool Vacuum gauge Assembly pliers Used for Centrifugal clutch Locking crankshaft Locating intake gaiter Withdrawing the fuel lter For M5 bolts Frame bearing Remove seal from clutch side Order no. 16-54 15-54 17-50 83-a 18-90 90-50 55-54 21-84 40-51 34-51 02-52 22-50 38-50 70-71 13-71 14-51 61-50 37-50 06-50 30-50 30-50 30-54 18-50 30-16

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Mandrel, sealing ring Removing crankshaft Connection to cylinder Adjusting ignition module Clamping the saw Centrifugal clutch Pressurisation during testing Fitting piston Checking ignition module Adjusting carburettor Removing crankshaft Vacuum test Fitting spark plug guard Fitting crankshaft Flywheel side Clutch side Removing crankshaft Fitting crankshaft seal
Sealing during pressure testing 11-02
21a Sleeve 21b Shaft extension 21c Shaft extension 24 Stop plate Assembly tool Crankshaft tool
Assembling spring, chain brake 67-01

Technical data

Displacement cm3/cubic inches CS 2149/W: 49,4 / 3,0 CS 2150: 49,4 / 3,0 CS 2141: 40,8 / 2,5 CS 2145: 45,0 / 2,75 CS 2147/C/W/H: 45,0 / 2,75 CS 2152/C/W/H: 51,7 / 3,2 CS 2156/C/W/H: 56,5 / 3,45 CS 2159/C/W/H: 59,0 / 3,6

Idling uneven

Carburettor leaking fuel
Flooding when engine not running
Idling (low rpm) Will not idle Adjust L screw Leaking air intake hose (rubber) Loose carburettor mounting bolts Loose or faulty fuel hose Fuel lter blocked Fuel line blocked Fuel tank vent blocked Throttle valve pivot stiff Throttle pushrod sticking Defective throttle return spring Bent throttle stop Faulty diffuser jet Adjust L screw Worn needle valve Needle valve set too high Worn needle valve lever Leaking control diaphragm/ cover plate Needle valve assembly sticking L screw requires constant adjustment

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
Remove the screws and carefully remove the cover from the chain brake spring. 4
Grip the clutch cover carefully in a vice. Release the brake spring by using the kickback guard from the saw as a tool. Engage it with the brake mechanism and turn anticlockwise to activate the brake.
Place one hand over the spring and insert a small screwdriver between the bottom end of the spring and the clutch cover. Carefully prise the spring upwards so that it slides onto the screwdriver shaft.

Cleaning and inspection

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. Measure the thickness of the chain brake band. It must be no less than 0.6 mm at any point. Lubricate the elbow joint with grease.

min 0,6 mm

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Chain brake reassembly

Bolt the elbow joint to the brake band and tighten to a torque of 11.5 Nm. Locate the elbow joint and connected brake band in their recesses in the clutch cover. Lubricate the recess for the spring with grease. 2 WARNING! Make sure the spring does not y out and cause injury. Wear eye protection.
Tension the brake spring by using the kickback guard from the saw as a tool. Engage it with the brake mechanism and turn clockwise to release the brake. 5 Turn the chain tensioner anticlockwise as far as it will go. Ret: guide bar chain clutch cover NOTE! After completing the repair the chain brake must be tested as described below.

Operating test:

The engine must not be running during the test. Grip the clutch cover in a vice. Compress the spring with special tool 67-01 and push it down with your thumb. 3 Guide bar length 38cm/15" Height 50 cm/20"
Hold the chainsaw over a rm surface. The height of the guide bar above the surface is given in the table above. Let go of the front handle and let the chainsaw fall towards the surface. When the guide bar hits the surface the chain brake must engage.

Fit the cover over the chain brake spring, tightening the screws to a torque of 11.5 Nm.

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Silencer removal
WARNING! Do not touch the silencer until it has cooled down, otherwise you may burn yourself. 1

Silencer retting

1 If the saw is equipped with a spark arrestor mesh this should be tted rst. 2 Ret cooling plate gasket silencer, tighten bolts to a torque of 810 Nm. silencer support cylinder cover 3 Run the saw for at least 1 minute, then retighten the silencer bolts to 810 Nm.
Chain catcher replacement
If the chain catcher is worn it must be replaced with a new one. Remove the cylinder cover, silencer support, silencer, gasket and cooling plate. 2 If the saw is tted with a spark arrestor mesh this must also be removed. 1 Release the brake by pushing the kickback guard backwards. Undo the guide bar bolts and remove the clutch cover, chain and guide bar. 2
Clean and inspect all parts carefully. If there are any cracks or other defects replace the damaged parts with new ones. The spark arrestor mesh is best cleaned with a wire brush. If the mesh is damaged it must be replaced. If the mesh is blocked the saw will overheat and this will cause damage to cylinder and piston. Never use the saw with a silencer that is in poor condition. Always use original parts.
Remove the chain catcher and replace it with a new one. Check that the vibration damping spring locates correctly against the crankcase when you bolt the new chain catcher in position. A worn (damaged) chain catcher on CS 2141, CS 2145 or CS 2150 can be replaced with the same chain catcher as CS 2149, (see gure above). 3 Turn the chain tensioner anticlockwise as far as it will go. Ret: guide bar chain clutch cover

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Stop switch removal
1 Remove the cylinder cover and air lter. 2
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.
Stop switch resistance measurement

2 Disconnect the red lead from the heater and connect a multimeter between it and the black earth lead that is bolted to the bottom of the carburettor on the clutch side of the saw. The meter should read 0.71.2 ohm. If the reading is higher replace the heater element. 3 Remove the air lter, throttle pushrod, rubber diaphragm and carburettor, see Carburettor removal. 4 Remove the bolt from the plate at the base of the carburettor to release the lead for the heater element. 5
Reconnect the leads and ret the cover. 3 Push the switch back into place and reconnect the leads. 4 Bolt the cover back onto the hand grip. Generator troubleshooting 1 Remove the cylinder cover and cover from the front hand grip. Disconnect the black lead from the generator and connect a multimeter between it and a clean area on the cylinder. The multimeter should show a resistance of 0.91.3 ohm. If the reading is higher or lower, replace the generator, see Replacing the generator. 20 English
Unscrew the three bolts from the front hand grip and remove the cover to reveal the leads. Disconnect the red lead.
Repair instructions 6 Rear handle heater Measure the resistance between F and Z. It should be 1 0.5 ohm. If not, replace the rear handle heater. Generator Measure the resistance between G and H. It should be between 0.31.3 ohm. If not, replace the generator. Carburettor heater Disconnect the lead at X and clean the connectors. Measure the resistance between X and G. The reading should be between 310 ohms. If not, disconnect the lead at Y and clean the connectors. Measure the resistance between X and Y, if the reading is not between 37 ohms replace the carburettor heater.
Unscrew the two bolts from the right side of the rear hand grip. Remove the throttle lock and throttle handle, see Throttle trigger. Pull out the heater element with the leads still connected.
Troubleshooting carburettor heater (CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W)
Operation The carburettor temperature is controlled by an electronic thermostat to eliminate the risk of ice formation in the carburettor. The thermostat switches on/off at 12C/54F. This means that the saw operator does not need to remember to switch the carburettor heater on or off. Troubleshooting Front handle heater Remove the side cover from the handle. Disconnect the leads at F and G (see diagram). Clean the connectors. Turn the switch on. Measure the resistance between F and G. The reading should be 41 ohms. If not, disconnect the lead at O and remove the switch. Measure the resistance between O and F. The reading should be 41 ohms. If the resistance is incorrect, replace the front handle. Disconnect the lead at N and G and measure the resistance between these points. The reading should be no higher than 0.1 ohm. If it is too high, replace the lead. Switch Measure the resistance between N and O with the switch turned off. The reading should be ohms or higher. Repeat the measurement with the switch turned on. The reading should be no higher than 0.1 ohm. If it is too high, replace the switch.

Clean the parts and check the following: The starter cord. The teeth on the pulley, lubricate with oil. That the pawls on the ywheel are undamaged, i.e. that they spring back towards the centre and move freely. Lubricate the return spring with light oil.
Replacing a broken or worn starter cord
Undo the four bolts that fasten the starter assembly to the crankcase and lift off the starter assembly. 2
Before replacing a worn starter cord the tension in the recoil spring must be released. Pull the starter cord out through the notch in the pulley rim and wind the pulley anti-clockwise to release the tension in the spring. 2 Remove the bolt from the centre of the pulley and lift off the pulley. 3 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152
Pull out about 30 cm of the cord and fasten it in the notch in the pulley rim. Release the tension in the return spring by letting the pulley wind backwards slowly. 3 WARNING! If the recoil spring is still under tension when the pulley is removed it can y out and cause injury. Wear eye protection.
Remove the bolt from the centre of the pulley and lift off the pulley.
Fit a new cord through the hole in the pulley and tie a knot to secure it. Feed the other end of the cord through the hole in the starter housing and through the starter handle, then tie a double knot in the end. Wind about 3 turns of the starter cord onto the pulley. Fit the bolt through the centre of the pulley and tighten to a torque of 23 Nm.

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Repair instructions Model CS 2156, CS 2159
Replacing a worn recoil spring
WARNING! Make sure the recoil spring does not y out and cause injury. Wear eye protection.
1 Remove the bolt from the centre of the pulley and lift off the pulley and spring. 2 Remove the broken recoil spring. For model 2159: remove the recoil spring cassette. Cleaning and inspection: Clean and inspect all parts carefully. If there are any cracks or other defects replace the damaged parts with new ones. Lubricate the return spring with light oil. 3 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152
Tensioning the recoil spring
1 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152 Fasten the starter cord in the notch in the pulley rim and wind the pulley about 2 turns clockwise. Check that the pulley is free to rotate at least another half turn when the starter cord is fully extended. Model CS 2156, CS 2159

Fit a new recoil spring, with the retaining wire still in place. Do not remove the wire until the spring is in position. If the spring comes loose when you put it in place wind it up from the outside working inwards. Lubricate the recoil spring with light oil. Model CS 2156, CS 2159
Lubricate the recoil spring with light oil. Fit the new recoil spring and cassette. Screw the cassette onto the cover using the two screws. 4 Fit the bolt through the centre of the pulley and tighten to a torque of 23 Nm. Tension the recoil spring, see Tensioning the recoil spring. 24 English

Starter assembly retting

Ignition module/ywheel removal
Position the starter assembly on the crankcase and tighten the bolts to a torque of 2.53.5 Nm.
Remove the cylinder cover. Disconnect the HT lead, remove the spark plug and t piston stop 15-01 in its place. Take off the starter assembly, release the leads from the cable guide and remove it. Model CS 2149, CS 2152: Remove the cover from the hand grip. 2

Ignition module testing

If there is a fault in the ignition system the ignition module must be tested before the ignition system is removed.
If replacing the ignition module, disconnect its leads and unscrew it. The ignition module can be left in place if you are simply removing the ywheel. 3 Test the ignition module as follows: Connect a test spark plug 13-01 to the ignition lead and clip the test spark plug onto the cylinder. Turn the engine over using the starter cord. If the test spark plug produces a spark the ignition module is OK.
Loosen the ywheel nut using a suitable socket and unscrew it until it is ush with the end of the shaft.

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Repair instructions 4
Replacing the generator, model CS 2147 W, CS 2149 W, CS 2152 W, CS 2156 W, CS 2159 W
1 Remove the cylinder cover. Disconnect the HT lead, remove the spark plug and t piston stop 15-01 in its place. Take off the starter assembly, release the leads from the cable guide and remove it. Remove the cover from the hand grip. 2

Position puller 90-02 over the magnets and counterweight on the ywheel. Tighten 23 turns and tap the head of the puller with a metal mallet to release the ywheel. Remove the puller, nut and washer. Lift off the ywheel.
Clean all parts, especially the tapers on the ywheel and shaft. Check that the ywheel is not cracked or damaged in any other way. Loosen the ywheel nut using a suitable socket and unscrew it until it is ush with the end of the shaft. Position puller 90-02 over the magnets and counterweight on the ywheel. Tighten 23 turns and tap the head of the puller with a metal mallet to release the ywheel. Remove the puller, nut and washer. Lift off the ywheel. 3
Unscrew the two bolts from the generator but leave the generator in place.

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Repair instructions 4 Remove the fuel hose and throttle pushrod from the carburettor. Unbolt the rear tank mounting from the crankcase, i.e. the rear vibration damping spring, and both stops. Lower the tank as far as it will go to allow access to the heater lead where it is connected to the tank. 5 Disconnect the generator lead from the hand grip and unclip it from the tank. Remove the generator and lead.
Ignition module and ywheel retting

Generator retting

1 Feed the generator lead through the holes in the crankcase and hand grip. Bolt the generator in position, tightening the bolts to a torque of 5 Nm. Clip the lead to the tank. NOTE! The lead connector must be positioned on the right of the clip, see diagram. Connect the lead to the connector on the hand grip. 2 Ret: fuel tank with both stops and rear vibration damping spring fuel hose to carburettor, hose length between tank and crankcase: 43 mm/1.69 inches and between crankcase and carburettor: 53 mm/2.09 inches throttle pushrod to carburettor ywheel with nut and washer cable guide, leads and starter assembly Remove the piston stop and reconnect the HT lead and cylinder cover. To ret the ignition module proceed as follows: Turn the ywheel so that the magnets are in line with the ignition module. Fit the ignition module with the plastic feeler gauge (34-01) held in position at the same time, without tightening the bolts. Connect the black earth lead to the front screw on the ignition module. Adjust the gap between the ignition module and magnet to 0.3 +/- 0.1 mm. The gap must be measured at either of the two lowest pegs on the ignition module. Tighten the bolts to 4.56 Nm. Connect the blue lead to the ignition module. Place the ywheel on the crankshaft. Turn the ywheel so that the key lines up with the keyway in the shaft. Fit the washer and nut on the shaft and tighten to a torque of 25-30 Nm. 2

D C B A

Fit the clutch and tighten anticlockwise as far as it will go. Then tighten to a torque of at least 20 Nm using tool 22-02. 3 Remove the piston stop. Fit the spark plug, tightening it to a torque of 15 Nm, then connect the HT lead. Then ret: cylinder cover guide bar chain clutch cover Unbolt and remove the clutch drum (A), RIM chain sprocket (B) if tted, needle bearing (C) and pump drive wheel (D).

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Remove the oil hose and lter (A). Model CS 2159 has two oil hoses. Model CS 2150: Push the housing up a little from the fuel tank and remove the lter (A) from underneath, see the diagram under Oil pump removal CS 2141, CS 2145. 7 Remove the pin (B) from the adjuster screw, using a small drift to press it out. 8 Press in the pump piston (C) so that the adjuster screw (D) can be removed. Remove the pump piston.
Loosen the chain guide plate, one or two bolts depending on the model. Model CS 2150: Remove the bolts on the anti-vibration elements on the same side. 5
Oil pump removal CS 2141, CS 2145
1-4 See Oil pump removal, models CS 2147, CS 2149, CS 2150, CS 2156, CS 2159points 1-4. Remove the bolts on the anti-vibration elements on the same side. 5
Unbolt the oil pump from the crankcase.
Carefully lift out the oil pump from the crankcase.

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Repair instructions 6
Oil pump retting CS 2147, CS 2149, CS 2150, CS 2152, CS 2156, CS 2159
Push the crankcase up a little from the fuel tank and remove the lter (A) from underneath. Lubricate the pump piston (C) with chain oil and t the pump piston and washers. 2 Press down the pump piston (C). Fit the adjuster screw and spring so that the pin (B) can be pressed into position. 3 Reconnect the oil hose and lter (A). Model CS 2150: Push the crankcase up a little from the fuel tank and screw on the lter (A) from underneath. WARNING! Poor chain lubrication can result in failure of the chain, which could cause serious or fatal injury. 4
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 all moving parts with chain oil.
Bolt the oil pump to the crankcase. The adjustable oil pump must be bolted to torque of 23 Nm.

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Repair instructions 5 Lubricate the needle bearing with grease. Fit the pump drive wheel (D), needle bearing (C), chain sprocket (B), if tted, and clutch drum (A). 7 Fit the clutch onto the crankshaft and tighten anticlockwise as far as it will go. Then tighten to a torque of at least 20 Nm using tool 16-02 and a suitable socket spanner or combination spanner (use clutch tool 22-02 for model CS 2159). 8 Remove the piston stop. Fit the spark plug, tightening it to a torque of 15 Nm, then connect the HT lead. Then ret the cylinder cover, guide bar, chain and clutch cover. Fit the chain guard plate, tightening the bolts to a torque of 23 Nm. Model CS 2150: Fit the bolts on the anti-vibration elements on the same side. 6 Models CS 2141, CS 2145, CS 2147, CS 2149, CS 2150, CS 2152

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
Insert the heating element between the air lter connection and carburettor as well as above the carburettor. Route the cable as illustrated above. Tighten the bracket above the carburettor with the two bolts. Connect the cables to the carburettor heater.
Connect the fuel hose to the carburettor. Ret the throttle pushrod at the same time as the rubber inlet manifold, press in the throttle pushrod so that it engages in the carburettor and t the spring. 38 English

Repair instructions 5

Carburettor heater CS 2147 H, CS 2149 H, CS 2152 H, CS 2156 H, CS 2159 H Retting

Heating element

Connect the leads to the stop switch.
Carburettor heater CS 2147 H, CS 2149 H, CS 2152 H, CS 2156 H, CS 2159 H Removing
Remove: carburettor 1 Remove the two screws from the clip above the carburettor. 1 Fit the heating element between the air lter connection and the carburettor as well as above the carburettor. 2 Tighten the bracket above the carburettor using the two bolts. 3 Connect the leads to the carburettor heater. Ret: carburettor
2 Disconnect the leads from the carburettor heater and remove the heating element. Heating element

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Air intake system removal
The air intake system comprises: inlet manifold insulating plate with clip carburettor ange impulse hose support ring 1 Remove: cylinder cover air lter carburettor HT lead starter assembly (CS 2141, CS 2145) Fuel tank (CS 2141, CS 2145) 2

Unscrew and remove the bolt from the silencer support. 4
Unscrew the four cylinder bolts. Lift up the cylinder so that the intake system insulating plate is free of the crankcase.
Unbolt the vibration damping spring between the cylinder and hand grip.
On models CS 2141 and CS 2145 there are cylinder bolts on the underside.

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Air intake system retting
Fit the inlet manifold (A) through the insulating plate in the carburettor ange cut-out (B), and check that the insulating plates impulse tube sits correctly in the inlet manifold. Fit the perforated brass support ring in the inlet manifold. Free the insulating plate from the cylinder by releasing the clamp using pliers. Remove the complete air intake system. 6 Remove: support ring carburettor ange from the inlet manifold insulating plate 2
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. NOTE! When replacing the impulse hose it must not be lubricated with oil or grease.
Fit the air intake system on the cylinder and snap the insulating plate into position. Check carefully that the impulse tube is correctly seated against the cylinders impulse channel. 3
Position tool 17-01 between the carburettor ange and the insulating plate.

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Carburettor adjustment
For instructions on adjusting the EPA carburettor see appendix A. Adjusting the carburettor involves adjusting the engine to the local conditions e.g. climate, altitude, fuel and type of two-stroke oil. The carburettor is equipped with three adjustment options. L = Low speed jet H = High speed jet T = Idling adjustment screw
Ret the carburettor. Screw in the carburettor bolts directly from behind without lifting the carburettor assembly, tightening to a torque of 11.5 Nm. It is important to hold the carburettor ange securely when tightening the bolts to prevent the inlet manifold from moving. 4
The L and H jets adjust the fuel ow to match the airow that the throttle valve opening allows. Turning them clockwise makes the fuel/air mixture weaker (less fuel in relation to the amount of air) and turning them anti-clockwise makes the fuel/ air mixture richer. A weak mixture increases the engine speed and a rich mixture decreases the engine speed. The T screw controls the throttle position when idling. Turning the T screw clockwise gives faster idling; turning it anti-clockwise lowers idling speed. WARNING! The guide bar, chain and clutch cover must be tted before the saw is started, otherwise the clutch may y off and cause injury. Basic settings and running in During testing at the factory the carburettor is adjusted to the basic factory settings. The factory settings are H = 1 turn and L = 1 turn. To ensure that engine components receive adequate lubrication (running in) the carburettor should be set to a somewhat richer fuel mixture for the chainsaws rst 3-4 running hours. This is done by adjusting the maximum speed to 6700 rpm less than the recommended maximum speed.

Hold the clutch side of the crankcase in a vice. Pull the crankshaft into its bearing using assembly tools 30-18.

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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.