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Joined: Jun 2015
Posts: 171
Likes: 4
Recycling and Repairs
I've hunted all sources and haven't found anywhere that describes how the chain brake handle return spring is fitted inside the handle of a Husqvarna 61/268/272XP Chainsaw chain brake assembly.
I have found the exploded IPL's showing the return spring, which I have included in the following photos, but nothing on how it is suppose to be mounted, or how it fits within the chain brake when re-attaching the handle to the mechanism/cover.
Existing chain brake handle (Complete 503727401) is damaged and missing pin 501874901 with circlips 735310820, and the brake assembly is missing the flat spring 501874701, band 503704001 and Pin 503240903.
As such, I purchased a complete replacement, but when the brake was pulled back to the released position, the handle sits right against the top handle bar grip and does not allow room to hold the chainsaw. As soon as the brake handle is touched, it returns forward to the full lock position due to main spring tension. I believe the handle should click into position then spring forward to allow you to hold the saw until pushed full-forward to activate the lock.
When I disassembled the replacement unit, I found the return spring just sitting up inside the top of the handle appearing to have no effect, so I pulled the pin from the handle, pulled the spring down and aligned the small hole of the spring so the pin went through it, but that didn't help.
Help needed please to work out what is going on.
Thank you.
Daryl
This is the return spring located inside the chain brake handle I need to know how it is suppose to be fitted and how it is positioned when mounted back on the brake assembly. Thank you.
[Linked Image]

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Last edited by Bushy260; 25/08/21 01:49 PM.

Environmentally friendly recycling at it's best
Joined: Jan 2015
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AVB Offline
SENIOR TECHNICIAN
Okay the spring in the handle is in the right position though it appears to be bent a little.
[Linked Image from i.imgur.com]

Joined: Jan 2015
Posts: 1,487
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AVB Offline
SENIOR TECHNICIAN
Now the brake band connects at the knee joint. The real challenge will get the that large compression spring back in place, They make a tool to do it but a c clamp or two and pair of extra channel lock pliers you can get it back in.

Now the following isn't the exact chain brake but it is the closest I can find showing how to assembly the knee, spring, and brake band. Just ignore the tri point piece on the knee as the your will be different so ignore fig 2 disassembly info. The instructions in the 61 service is for an old style brake assembly and is of no use here.
[Linked Image from i.imgur.com]
If you notice in fig the fork tool Husqvarna uses. Ignore fig 9.
[Linked Image from i.imgur.com]

Sorry taking a while to respond as I had to the new chain brake here to make sure of the handle spring positioning.

Joined: Jun 2015
Posts: 171
Likes: 4
Recycling and Repairs
Thank you AVB for your quick reply.
I sat at my computer desk with the old and new assemblies in front of me whilst looking at the IPL and individual parts oline. I worked out that the handle return spring was now bent more than the picture of one I found online, and it that just sits right up inside the handle where I found it, and is above the PIN going through the handle. That is, the PIN that activates the brake knee joint does not go through the small loop hole, and that the small spring loop hole appears to keep the end of the spring off the side of the handle to create the spring return action.
All the YouTube videos I found showed the brake assembly you have in the IPL above. I couldn't find any videos on the handle of the 61/268/2725XP.
I compared everything between the original assembly with the new non-genuine assembly I purchased, which have identical part numbers on both the cover and handle, and even the knee joint sits in the same position, so I can't work out why the non-genuine break position is against the handle bar when in the brake band is in the released position.
I requested a return of the new non-genuine one, but since I dismantled it to see if I could get it situated correctly, then that is no longer an option, so I now have future spare parts to sell off and ordered a replacement, but different non-genuine assembly, from another supplier.
Will compare both replacements and provide follow up comments on the outcome.
I don't have a decent mobile or camera to create a video on this model brake assembly to post on YouTube for others who may have a similar issue.
Thank you again for your assistance.


Environmentally friendly recycling at it's best
Joined: Jan 2015
Posts: 1,487
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AVB Offline
SENIOR TECHNICIAN
I use to do this a lot but it been over 8 yrs since I did the last one So I am very rusty on it. But can atest how hard they are to reset off the saw. Even the one that give copies from the service I end making a reset tool to fit it so I could use a pull bar.

I do know the handle should spring forward on a properly assemble unit or at least the new OEM one I have here does.

I seem to remember that handle spring has to left out until the knee joint is set and then put back in so the handle will spring forward but as I said the cobwebs are in the way.

1 member likes this: Bushy260
Joined: Jun 2015
Posts: 171
Likes: 4
Recycling and Repairs
Yeah. Finally worked out the answer to my dilema.
The 2nd replacement assembly I purchased turned out to be identical as the first and, again, it did not allow the handle to release forward without activating the brake again, so back to the drawing board I went.
Sitting here this monring playing around with pieces of the original, and by accident, the answer came into play.
It was the end of the Handle Return Spring 503 57 97-01 that was not sitting in the centre of the handle correctly allowing it to slide into the slot in the top of the main brake cover to activate the forward return of the handle against the front of the knuckle 501 87 53-03 as it was jamming on the side of the leg of the flat control spring 501 87 47-01.
Hopefully, these three photos may explain it better. Sorry for not being in correct focus, as mobile is rather crappy (cheap).
1. Shows how the end of the spring has been adjusted (bent) so it now sits in the centre of the handle to alight with the slot and the knuckle.
2. The knuckle has been pulled back where the brake would be in its released position to allow the chain to activate.
3. Now has the alignment of the handle return spring sorted with the slot in the cover, the knuckle, and the flat control spring (item is missing in photos).
Maybe this will help someone else who can't work out why the handle doesn't sit where expected.
Daryl

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