Chainsaw Repair

Husqvarna - Stihl - Poulan - Jonsered - Dolmar chainsaws and more => Jonsered => Topic started by: farmboy on September 19, 2011, 09:28:14 am

Title: Jonsered 535
Post by: farmboy on September 19, 2011, 09:28:14 am
Picked up a 535 much to my dismay the piston is completely worn out.  The skirt on the intake side is so thin it should have broken .47mm wear.  Anyway, went on the hunt for a piston last night.  Did not realize pistons are not available OEM or AM.  It's open port with a windowed piston.  Went to my piston drawer to look for a 45mm that would work.  A Husky 51 45mm is real close no windows tho.  Haven't finished measurements yet.  Are there any other piston options?  Since it's open port won't the non windowed piston work?  It's not worth cutting windows.  Just making a runner.  Pretty nice little saw appearance wise.  I do know I'll be checking for piston availability before I pick up another older saw. ANOTHER lesson learned!
Shep
Title: Re: Jonsered 535
Post by: Cut4fun . on September 19, 2011, 03:56:23 pm
Just some WAG's on 45mm windowed pistons. I'm not sure so check them out.

Husqvarna 45mm 353 piston, Husky 51 55 45mm, Jonsered 590 45mm I know is.

Others to look at windowed  ???  dont know about pin mm etc. stihl 029 45mm   031 032 

NON windowed 45mm partner 500 
Title: Re: Jonsered 535
Post by: Old Iron Logging on September 19, 2011, 07:14:37 pm
254 is a nice windowed 45mm, just wrong pin size.
Title: Re: Jonsered 535
Post by: farmboy on September 19, 2011, 10:07:08 pm
Thanks for quick replies.  I always grab a 254 piston when I need a 45mm knowing has a larger pin.  I'll learn someday.  I'm probably just going to put the 51 non windowed in and call it good. 
Shep
Title: Re: Jonsered 535
Post by: farmboy on September 22, 2011, 07:51:13 am
Info 51 45mm  piston won't work.  Small end of the 535 rod is about 10mm smaller than 51.  Also, skirt is longer on the 51 no big deal to cut down.  Search continues will look for specs on the 029 45mm next.
Shep
Title: Re: Jonsered 535
Post by: nmurph on September 22, 2011, 08:03:44 am
Here are 2 that are 45mm. I don't know about any other dimensions or whether or not they are windowed.

032
Shinny 575
Title: Re: Jonsered 535
Post by: farmboy on November 19, 2011, 10:13:09 am
Found a NOS piston.  However, guy wants a lot more than I'm willing to pay to get a $75.00 saw running.  Cut skirts and lowered the area below pin bosses on a Husky 51 piston to match up with OEM.  Gonna put it in there and see what happens.
Shep
Title: Re: Jonsered 535
Post by: Cut4fun . on October 14, 2014, 03:32:24 pm
Saving info from Mitch mweba     ;) 8)

Jonsered 535 piston specs

35.4mm tall
pin height 13.8
skirt 29.66
wrist width 10.52
pin 10mm

(http://farm9.staticflickr.com/8206/8248071059_59b2894d41_z.jpg)



Title: Jonsered 535
Post by: 67L36Driver on November 06, 2014, 05:40:59 pm
I have a 535 on my bench from a friend.  Maybe it is just tired and worn a lot but can't get a good tune on the carb.

Are they worth putting in a piston/ring(s)?

I'll try a diaphragm and gaskets next.  Prolly old and stiff.

Cancel the carb rebuild.  Pumps 115 psi.  Done for.
Title: Re: Jonsered 535
Post by: farmboy on November 06, 2014, 09:44:27 pm
Pistons are NLA.  Scarce but can be found.  Maybe just a ring will freshen it up.  The last one I tore down the intake side of the piston was almost worn away.  It was thin i mean thin.  Its been in a box on the shelf for a couple of years.  Have to look into maybe another model piston could be modified to fit.
Shep
Title: Re: Jonsered 535
Post by: 67L36Driver on November 07, 2014, 06:04:34 am
Excessively worn piston seems to be a result of the nylon mesh air filters on many saws.  Let's too much abrasive dust in.
Title: Re: Jonsered 535
Post by: 660magnum on November 07, 2014, 06:54:26 am
Fines are a real problem in some areas with some woods.
Title: Re: Jonsered 535
Post by: Cut4fun . on January 23, 2015, 08:30:44 pm
They have a aftermarket 535 piston now. http://www.ebay.com/itm/JONSERED-535-PISTON-KIT-45MM-REPLACES-PART-503163801-NEW-/181636507813?pt=LH_DefaultDomain_0&hash=item2a4a6128a5
Title: Re: Jonsered 535
Post by: 660magnum on January 26, 2015, 02:17:37 pm
Maybe this was posted earlier?

http://store.chainsawr.com/products/jonsered-535-chainsaw-piston-and-cylinder-set
Title: Re: Jonsered 535
Post by: Cut4fun . on January 26, 2015, 02:58:52 pm
I had seen that before. But most folks only want the pistons. The saw is hardly worth that whole. all JMO
Title: Re: Jonsered 535
Post by: leec on December 19, 2015, 06:22:29 pm
I did find an AM piston for a 525 at Chainsawr for reasonable price.  Not sure it's the same size
Title: Re: Jonsered 535
Post by: leec on August 06, 2016, 07:48:48 am
I put a new piston into my 525 and it runs well.  Now my problem is no oil from oiler.  Where is the oiler, inside the crankcase?  Do you have to split the case to service?  I can't see any filter or line in the oil tank, or where the line would attach.
Title: Re: Jonsered 535
Post by: Cut4fun . on August 06, 2016, 08:16:22 am
I dont know saw.  IPL shows a oil line and filter, etc.

Jonsered 535 IPL http://s30387.gridserver.com/partsDiagrams/Jonsered%20535.pdf
Title: Re: Jonsered 535
Post by: leec on August 06, 2016, 09:35:06 am
Yes I saw that and it looks like it is inside the crank case.  One of the really annoying things about Jonsered ipls is that there is no description of each part only a number.  I put kerosene in the oil tank in the hopes of clearing the line.  No luck yet
Title: Re: Jonsered 535
Post by: leec on April 30, 2018, 01:42:23 pm
I found and purchase a piston from Red Barn, put it in and saw runs just fine. $25.00 if I remember correctly