Husqvarna 61 project results

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Cliff R

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Just got the Husqvarna 61 Rancher up and running. It was bought off of E-Bay, a 1983 model.

The piston/ring/jug were messed up a bit. Aside from one very minor scratch in the lowest portion of the jug on the exhaust side, the jug cleaned up fine, as did the piston. I bought a new Husqvarna ring for it, prepped the cylinder walls and kitted the carburetor.

I couldn't resist the opportuninty to do some minor port work, which included the intake manifold, intake elbow, and replacing the throttle and choke flap screws with smaller headed screws. The muffler is still stock, other than removing the divider/screen.

I widened the exhaust port some, and the intake a bit less. Basically just a smoothing up/blending of all the surfaces. The compression came WAY up on the saw, and it idles and runs flawlessly.

The power level is increased, as it should have been since the compression was WAY down before I made the repairs. It's difficult to evaluate the port work, since it didn't have much power before the changes.

At least is doesn't appear that I messed up the timing or anything, idles great, throttle response is fine, plenty of "grunt" when cutting. It doesn't have nearly the power of my 268XPS, at any rpm, and runs much slower in rpm's at peak power. Overall, it really doesn't cut any faster, if as fast as my muffler modded 55. It seems to have a bit more mid-range torque, but the chain speed is noticably slower, and the engine just doesn't SCREAM up to the high rpm's I'm used to from my other Husqvarna saws?

I'm just guessing, but the 268 (and probably the 55) must have considerably different porting to the jug, or is a different design altogether? In any case, the 61 will just sit most of the time, until I can obtain and intake for it, and upgrade to a 268/272 piston/jug......Cliff
 
Muffler mod is next, just wanted to get an overall idea as to how the basic stuff I already did was going to work.

The saw is not overly impressive, but a good solid performer. I worked on some larger stuff with it today, so I could completely bury the 20" bar, and it did fine. Definetly NOT in the same class as the 268, but just OK. Still a far cry better than a lot of the stuff I've ran over the years. Power seems very similiar to the 038 Stihl's I used to own.....Cliff
 
The 61 was never a screamer or top performer, since it was probably designed in the mid 70's. Some of the 55's had closed port jugs, yours may be one of those which is why it can hang with the 61. You hit the nail on the head, they were very dependable, not very flashy saws that led up to the high performance pro models like the 162, 154/254, 262, etc
 
Huskyman, thanks for the reply. I pulled the carb back off yesterday, suspecting a plugged off idle discharge hole, and sure enough the first hole behind the throttle plate was plugged up (I missed it during the carb rebuild). I wondered why I had to set the idle mixture so rich to avoid a very slight bog off idle.

Anyhow, I ran another tank of fuel thru it, finished cutting up a big tree that went down on our property in the last storm, and it faired quite a bit better. Still not overly impressive as a high rpm saw, but decent. It does have a LOT of upper mid-range power, and lugs quite well. At least my home "port" job didn't mess it all up.

The 55 we have is a very impressive cutting little saw, but I have no idea which jug was used on it? I call it the little "beast". I grabbed it up dirt cheap on E-Bay, with the ring stuck in the piston. It's not even the larger piston assembly, but it flat ROCKS, so I'm assuming it's got the better jug. The little 55 has quickly become one of my favorites, as I'm loving smaller/lighter saws these days.......Cliff
 
I thought about that when I put the jug back in place, but didn't have any suitable sealer other than RTV.

I also tried to set the jug up in the shop lathe during the overhaul, but couldn't find the proper combination of tools/cutters to remove a few thousanths from the gasket sealing surface.

It does have very good compression after the rebuild, which is probably what brought most of the power back. I doubt if my home "port" work did a whole lot for it, since I didn't remove any material at the tops or bottoms of the ports to change the timing.

Muffler mod is next, after I put a few more hours on it and get everything seated in.....Cliff
 
Hello Cliff R,

I see in your signature that you also own a Husky 480CD. Is that a nickname for a Husqvarna 480CD?

I'm looking for all information I can get about this saw (manuals, partlists), but on internet this chainsaw seems to be disappeared...

I bought the saw second-hand, it started very easy and idle speed was OK. I filled het up with Aspen. But after 2 serious cuts it stopped running. I took the saw to a repairshop, the man said there was cylinder damage ?!?!

I still have to take it apart myself to see how serious it is, but I never did a chainsaw revision so could you give me some advise how to start?

Many thanks in advance,

Guido.

PS: I live in Belgium
 
Yes, our 480CD is a Husqvarna. I bought it new in 1982, and the only thing that's ever been done to it is to braze the end of the carb linkage to the shaft as it got loose after about a zillion hours of use.

They are very well made saws, and some parts are still available for them. Many consider the 480 a big underpowered for the weight. I have never felt that way about ours, but it is maxed out with a 24" bar, and doesn't run quite the rpms at full power as the newer models. It's still PLENTY of saw for serious work, if you don't mind the weight.

The muffler and carb/intake need to be removed to get the jug off of the case. More than likely the saw leaned out some and melted some aluminum over the ring and onto the jug. In a lot of cases repairing the problem is quite easly, with at most buying a new ring and maybe a piston.

I bought my Husky 55 and the 61 with damaged jugs, and repaired both of them with only buy a ring for the 61. We were able to clean up the jug/piston/ring on the 55 without buying any parts.

The best course of action is to take it apart, and evaluate the damage, then develope a course of action for repairs. Pistons and rings are readily available, and once in a while we see complete jugs and other parts for sale, still new in the box. I just scored a new top cover for mine, after looking for one for several years......Cliff
 
Thanks Cliff for your very positive comment! As soon as i can find the time I will take the saw apart to make a diagnosis. But I'm running out of time because I have several beech trees to cut (50-75 cm) and my Jonsered 2149 Turbo is a bit to small for the job i believe :mad:
 
Guido, you may be remarkable surpised at how easy it is to get a jug, ring and piston cleaned up and back in service.

The Husky 55 in my line-up was a MESS when we pulled it down. The piston had smeared quite a bit of aluminum over the ring, and some onto the jug.

I very carefully removed all the material, cleaned up the jug and lightly honed it with some auto body sandpaper.

The ring even cleaned up fine. It went back together, fired right up and runs flawlessly. I just ran it last night for about an hour.

Don't worry about minor scratches in the piston, the jug and the ring are most important......Cliff
 
Hello Cliff,

I did some work on the 480CD. I took it apart, there were indeed minor scratches on the cylinder (only below the output port), some more on the piston. I polished them with very fine waterproof sandpaper. Put everything together, also found a 2 times brokel fuel line.

With new fuel line I managed to tune the carb and have the saw running. Low and High speed were good adjustable. Just on the edge of "4 stroking". Response to the throttle was good.

I first did some light cuts (30 cm) and it performed very well. But on the second 80cm cut the saw slowly started to "blubber" and finally stopped. Adjusting the carb was impossible. No damage was visible on cylinder or piston, but compression was low.

I ordered a new piston and rings and assembled it all together again. But compression stays low and the saw doesn't run.

When I compare it to my Jonsered 2149 Turbo the "bumps" you feel when pulling the starter rope are much less, but I would expect a lot more of a 80cc motor!

So I think the cylinder is worn out, allthough I cannot see much on it. I found an assy on

http://www.hyperparts.com/wc.dll?ctwp~getitemclass~1001~1003~1~part~632-144

But they don't ship to Belgium :censored:

I guess for this moment will be the end of this part. Today I'm going to buy a Husqvarna 365 (I want to get rid of the stack of trees in front of my house :dizzy: ) I can get it with a 10% discount.

I will keep the 480 as a "hobby project", maybe it will run again someday!
 
Hello Cliff,

I did some work on the 480CD. I took it apart, there were indeed minor scratches on the cylinder (only below the output port), some more on the piston. I polished them with very fine waterproof sandpaper. Put everything together, also found a 2 times brokel fuel line.

With new fuel line I managed to tune the carb and have the saw running. Low and High speed were good adjustable. Just on the edge of "4 stroking". Response to the throttle was good.

I first did some light cuts (30 cm) and it performed very well. But on the second 80cm cut the saw slowly started to "blubber" and finally stopped. Adjusting the carb was impossible. No damage was visible on cylinder or piston, but compression was low.

I ordered a new piston and rings and assembled it all together again. But compression stays low and the saw doesn't run.

When I compare it to my Jonsered 2149 Turbo the "bumps" you feel when pulling the starter rope are much less, but I would expect a lot more of a 80cc motor!

So I think the cylinder is worn out, allthough I cannot see much on it. I found an assy on

http://www.hyperparts.com/wc.dll?ctwp~getitemclass~1001~1003~1~part~632-144

But they don't ship to Belgium :censored:

I guess for this moment will be the end of this part. Today I'm going to buy a Husqvarna 365 (I want to get rid of the stack of trees in front of my house :dizzy: ) I can get it with a 10% discount.

I will keep the 480 as a "hobby project", maybe it will run again someday!


Hello Bluescoobie, where are you in Belgium ? I have a 380 CD in good condition for sale at this moment, as it is too young a saw for collecting imo. I live near the city of Tongeren. I also can try to help you out on restoring your 480.

regards,

Roland

480cdc.jpg
 
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Hello Roland,

Would be nice if you could help me to restore the 480CD! I live in Eksel, between Lommel and Hasselt. I sent you a pb. I'm not shure I want to buy the 380CD, I hope you can understand I don't want to start a new project again. I think 480CD is good now, except for the cylinder. Carburetor, Ignition, starter rope & spring, crank everything OK. Hope to hear from you.
 
Hello Roland,

Would be nice if you could help me to restore the 480CD! I live in Eksel, between Lommel and Hasselt. I sent you a pb. I'm not shure I want to buy the 380CD, I hope you can understand I don't want to start a new project again. I think 480CD is good now, except for the cylinder. Carburetor, Ignition, starter rope & spring, crank everything OK. Hope to hear from you.


It was just an offer, so need to feel obliged. Eksel is not too far away. You have pm.
Are you sure the cylinder on your 480 is shot ? It's very uncommon to really wear them out, or did you use very abrasive material to clean it.

I am not sure either if the top end of a 380/480 is shared with other Husky models, maybe Sawtroll or Spike could comment on that. On german ebay there are sellers of lots of Husky aftermarket cylinders and pistons.
 
A few minor scratches in the bore shouldn't be a problem. I've managed to salvage some cylinders and pistons that looked like someone ran gravel thru them. Our most recent 61 project had some pretty good transfer of material from the piston to the jug. After preparing the bore there was only one minor defect in the bore just below one of the port openings. A new Husqvarna ring and it's running fine with excellent compression.

The 480 that we have is very diffucult to pull, you have to put it on the ground and stand on it, a compression release would have been a nice feature on that model!

In your comments you mentioned that the saw was running them died out? Have you checked the tank vent, ours plugged once and it would stall out after a minute or so of running?.....Cliff
 
Well some way or another the compression is gone, and until now I don't get how. Maybe I got the wrong piston rings ???? I measured the bore and it's 52mm, the new piston is 51.6 or so mm. Is that way to little?

I used very fine waterproof sandpaper and only polished the scratched part below the output port.
 

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