Chainsaw Repair

Husqvarna - Stihl - Poulan - Jonsered - Dolmar chainsaws and more => Husqvarna => Topic started by: fatboycowen on February 04, 2013, 04:52:07 pm

Title: New project - 385xp
Post by: fatboycowen on February 04, 2013, 04:52:07 pm
Hello again.  I have a new project that i will need some help with.  If you can put up with me, here goes. My plan is to document everything with this thread, with the hope of helping future noobs like myself. I also have about a billion questions to ask.

I picked up a 2005 385xp.  The saw was used by a logger, and is well used.  However, i put bar oil and mix fuel in it, and it fired right up with just a few pulls. Seems to run great, and is strong.  It has 160psi.  It appears to be bone stock. I only had the chance to make a few cuts with it.

It does have a few issues that i wanted to address, and it's dirty as hell, so i decided to start taking it apart to clean and fix the issues.

Known issues (before breakdown)
- fuel vent is present, but it leaks when the saw is tipped
- Clutch springs are weak
- Sprocket is WORN
- Clutch drum is very worn

Here are some photos. 
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 04:56:01 pm
Before i forget - Does anyone have a repair manual for this saw?  I have the IPL.

I started by removing parts, and degreasing and cleaning them. 

More pics
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 04:57:12 pm
more
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:02:00 pm
The case has a leak below the muffler.  A little bar oil seeps through at the gasket.  The muffler gasket is also missing.  The aluminum heat shield piece was still in place, but gasket missing.

This saw has a Walbro carb.  The IPL shows a Tillotson.  Any ideas on this?  I don't know which model it is.  Not sure where to find the model number.

More pics:
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:05:47 pm
At this point, i didn't see the point in stopping, so i pulled the jug. First time i've done this. Here is what i found.

The cylinder looks like it's in great shape.  Very smooth on the inside, no scoring.  There is one fin partially broken off, but it doesn't seem like a big deal.





Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:08:38 pm
The piston seems to have some wear.  The machine marks on the lower part are no longer there. It's just very smooth. 

I took a ring off (didn't get pictures) and it seems to be in good shape.  I put the ring in the cylinder, to get an idea of the end gap.  It's not very wide, but i didn't put a feeler gauge on it yet. 

Does this look like the original piston?  Should i plan to replace the piston?  What about the rings?
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:13:59 pm
Here is where it gets ugly.  At this point, the cylinder is off, but the clutch and flywheel are still on.  I swear i can feel a tiny bit of play on both ends of the crank shaft.  It may need crank bearings. 

I checked the big end crank bearing, and i can't feel any play at all. It seems tight.  I was able to view parts of the crank bearings, and it looks like all of the balls are present, along with the bearing cage.  I have never split a case before. 

Now, with the carb base removed, i can see the tank vent line.  There is a green piece that goes into the tank, where the line attaches. I think this is where it is leaking. The green part is loose inside the tank hole. By grabbing the vent line, you can move the green part in and out very easily. 

I haven't pulled the fuel tank yet.  I was hoping someone had a repair manual before i get too deep. The parts box is getting pretty big, so i hope i can remember how this thing goes back together.
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:17:07 pm
This front AV mount seems to have a problem.  It has play in it, where it meets the tank.  The spring is not broken, but something isnt right about it.  The pics are an attempt to show how much it can move (probably almost 1/2")
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 05:21:01 pm
The case has a broken piece just above the flywheel.  How important is that piece?

Also, how do i get the flywheel off?

I don't have a tool that will fit the clutch.  I might just weld something to a socket to fit in there.  Any tricks to removing a clutch without the proper tool?  I do have a piston stop.

That's it for today.  Any help or comments (positive or negative) are appreciated.

Thanks.
Jon
Title: Re: New project - 385xp
Post by: Cut4fun on February 04, 2013, 05:27:17 pm
Nice thread. I have never owned a 385 so I am going to watch and learn too. 

I had a 2171 that had that whole piece above flywheel missing, never noticed any issues.   

Early 385's were know for bad crank bearing issues.

Side of carb should have a couple letters then numbers to tell you what it is.

Did anyone PM you a 385 service manual?  If not I will look to see if I have one.
Title: Re: New project - 385xp
Post by: Cut4fun on February 04, 2013, 05:28:30 pm
Clutch tool you can make them out of old sockets.
Title: Re: New project - 385xp
Post by: Cut4fun on February 04, 2013, 05:49:19 pm
Let me know if you still need the husqvarna 385 service manual. 

I will need to load it off my CD to my puter then email it to you.
Title: Re: New project - 385xp
Post by: rayvil01 on February 04, 2013, 07:54:40 pm
Great thread and pics.  I bought a 395 XP off of ebay about 4 years ago.  (Guy shipped it USPS with a 1/2 tank of gas in it.  Post Office people were not real happy about that...but, that's another story.)  Very similar saw.  I didn't pull the jug.  But, I had to replace the whole brake assembly/ right side cover, replace all the tubing, Oil pump, strainers...all that kind of high mileage stuff.   

Clutch tool I made out of a socket using an angle grinder like Cut4fun said.  Works like a champ.

If you peel off that black plastic air cowling around the flywheel you can get a bearing puller in there.   Take it easy on the wire keepers.  They're little tabs of plastic and will break easily. (Don't ask me how I know that.    :-[)
I'm sure there are tricks to make a home made flywheel puller.  but, I bought  one about 15 years ago and there's no getting around how valuable it is when I need it.  Get one that you can configure for three jaw or two jaw operation.  Get a little tension and tap the puller shaft with a leather or soft blow mallet.   If you're gentle with it, a little Kanokroil around the shaft will help.  I have heated stubborn flywheels with a heat gun.   I'm always timid with flywheels. 

Looking forward to seeing the rest of your project.  I'm sure I'll learn a lot from the veterans as you go through it.  Good luck. 
Title: Re: New project - 385xp
Post by: 660magnum on February 04, 2013, 08:01:25 pm
This front AV mount seems to have a problem.  It has play in it, where it meets the tank.  The spring is not broken, but something isnt right about it.  The pics are an attempt to show how much it can move (probably almost 1/2")

There is a plastic threaded boss on the plastic that the spring threads onto.

See if you can tighten the spring onto the plastic boss? You may have to remove the crankcase from the tank to get to it?
Title: Re: New project - 385xp
Post by: 660magnum on February 04, 2013, 08:02:40 pm
I have the illustrated parts list and the repair manual if you need it but will have to email them to you.
Title: Re: New project - 385xp
Post by: fatboycowen on February 04, 2013, 08:29:55 pm
I still need the manual. I already have the IPL.

If you can, email them to me.  I believe my account set to receive emails from users, so it should work.

Thanks!

I'm going to continue disassembling the saw soon. I'll keep the pictures coming.

Title: Re: New project - 385xp
Post by: Cut4fun . on February 04, 2013, 08:32:17 pm
I have the illustrated parts list and the repair manual if you need it but will have to email them to you.

Go ahead and send yours. I dont have the service manual on my HD.
Title: Re: New project - 385xp
Post by: 660magnum on February 04, 2013, 10:34:57 pm
JC, look in your email for the manuals
Title: Re: New project - 385xp
Post by: fatboycowen on February 05, 2013, 06:32:30 am
Got the manual.  Thank you very much!

What does everyone think about the piston in this saw?  Should it be replaced? 
Title: Re: New project - 385xp
Post by: 660magnum on February 05, 2013, 06:38:37 am
The piston has some skirt wear and it would be best if you could put a new Meteor piston in it.

However, the saw will run to clean the piston and put new Caber rings on it but down the road you may have a skirt breaking or spit back through the carb.
Title: Re: New project - 385xp
Post by: mdavlee . on February 05, 2013, 06:10:53 pm
I would put a new piston in it and run it. You can use a steering wheel puller to pull husky fly wheels. Just use the bolt holes that hold the pawls on with longer metric bolts.
Title: Re: New project - 385xp
Post by: fatboycowen on February 06, 2013, 08:34:12 am
Last night i continued to tear the saw down. I removed the clutch (wow, it was on tight). I got the flywheel off. Used a 2 jaw puller, put a light load on it, then gently heated with a propane torch.  It popped off in a few seconds.  Flywheel is good. Flywheel key is present.

Then, i removed the oil pump.  DIRTY!  I found a big problem.  The play i was feeling in the crank was between the crank shaft and the inner bearing race.

When rotating the crank shaft with fingers (very smooth, almost no resistance), the inner race DOES NOT MOVE.  The crank spins inside the inner race.  However, i can easily move the inner race around with my fingers, so the bearing has not seized.  There is noticeable play between the crank and the race.

After removing the piston, i can feel a tiny bit of play in the big end bearing. It's very hard to judge this, especially with my limited experience.

So, i assume this means i need a crank shaft. This thing is turning into a money pit.  It's certainly not worth what i paid for it. But, at least i am learning. My wife is actually encouraging me to spend money on this thing to get it right, believe it or not.

I can get (what i think is an OE) crank shaft for around $220 with bearings and seals.  I already have a line on a meteor piston kit as well. 

Are there any other reasonable options for the crank shaft?  I hesitate to look for a used one.  Are aftermarket cranks even worth considering? I see them on Ebay for around $80.  I don't believe that includes bearings and seals, so that saves me around what, $100?

Thoughts?

The only step left is splitting the crank case. I have to build a tool, so that may take some time. I'll post pictures later when i get them uploaded. 
Title: Re: New project - 385xp
Post by: 660magnum on February 06, 2013, 09:29:22 am
Your experience and thoughts are typical for that engine.

Enjoy and good luck with your project. Take it one thing at a time.
Title: Re: New project - 385xp
Post by: mdavlee . on February 06, 2013, 07:04:10 pm
I don't think the china cranks have had good luck. I would probably stick with oem for the crank for that saw.
Title: Re: New project - 385xp
Post by: fatboycowen on February 06, 2013, 07:36:17 pm
So, tonight i split the case.  I think i used the redneck-iest version of the redneck method, but it worked very well.  I didn't feel like welding.  I prefer to weld outside since i only have a 1 car garage. I was very surprised how easy it was. The tool took maybe 15 minutes to make, and i had the case in half in around 10 more minutes.



Title: Re: New project - 385xp
Post by: fatboycowen on February 06, 2013, 07:40:44 pm
The top picture is a closeup of the end of the crank that was spinning in the bearing.  If i was confident in the big end bearing, i could probably score this area, and press on a new bearing. 

When i pushed the crank out the opposite side of the case (after splitting), the bearing came out of the case and stayed on the crank.  The case looks good on both sides.  But, man are those bearings tight in the case. I'm wondering how in the world i can press this thing back together.

What is the best method for this? I have seen some people put the bearings on the crank first (easy if you freeze the crank, and heat the bearings).  But, how then would i press the crank into the case half, and then put the two halves together?
Title: Re: New project - 385xp
Post by: 660magnum on February 06, 2013, 10:40:05 pm
You can do the same way after you get the bearings on the crank you put them in the freeze and then heat a case half and drop the crank and bearing in. Then put that all in the freezer and heat the other case half etc.
Title: Re: New project - 385xp
Post by: fatboycowen on February 07, 2013, 07:22:36 am
Ah, that makes sense. Which case half should i push the crank into first? 

The bearings that came out of the saw had plastic in them.  I assume if the new ones do, i won't be able to heat them.

It turns out that the front AV mount bolt was simply very loose.  I removed, inspected, then tightened it back into the tank, and it seems firm. 

The AV mount on the cylinder has a rounded out threaded hole on the plastic end. So, i'll replace that one.  The rest of them are fine. 
Title: Re: New project - 385xp
Post by: 660magnum on February 07, 2013, 08:12:45 am
My experience with old chainsaws is that people have poor response to a loose bolt. I one gets loose, it will stay that way until it ruins the hole and the bolts gets lost.

The worst ones are where a non owner uses the chainsaw.
Title: Re: New project - 385xp
Post by: mdavlee . on February 07, 2013, 06:18:06 pm
I heated the halves up in the oven when I did a 390 crank. I put the bearings on the crank first with a socket on the inner race with a 1/2 socket. If I remember right you can use the oil pump as a guide for how far to seat it. I seated that side first and then the starter side. Heat the case halves to around 250 for a half hour or a little longer. You could support the case good and use a large socket to drive the bearing out. I think one side stayed in and the other stayed on the crank when I split the case. My case splitter is almost identical to yours.
Title: Re: New project - 385xp
Post by: fatboycowen on February 08, 2013, 06:31:47 am
Great advice.  I found the video in the how to thread that explains it really well. 

I'm really glad i had the opportunity to dig this deep. It's been a fun learning experience. 
Title: Re: New project - 385xp
Post by: 660magnum on February 08, 2013, 09:00:00 am
Here is a member's technique

http://www.youtube.com/watch?v=naiSPM-r97A&list=UUXrUSTTnD1KfjS6rJBCxhhg&index=16

http://www.youtube.com/watch?v=AGE1pFEUYrs&list=UUXrUSTTnD1KfjS6rJBCxhhg&index=15
Title: Re: New project - 385xp
Post by: fatboycowen on February 08, 2013, 11:15:23 am
Yep, that's the video i found.

It's nice to see the methods that are successful in a video.  Certain things cannot be easily described in words.

One thing i was always worried about was pounding on the crank shaft.  It's a straight rod with a big offset in the middle of it.  But, i can see in the video that a mild hit to the knocker won't damage it. 

When all my parts come in, I'll give it a go and see what happens. I may not use these exact methods, but I'll figure it out.  I'll continue the photos.
Title: Re: New project - 385xp
Post by: 660magnum on February 08, 2013, 11:42:46 am
Take note that Mitch used a soft face dead blow hammer.

I have a 372 crank that someone used a steel hammer on and they peened over the flange for the rim retaining snap ring.