The Husqvarna 235 is a lightweight, professional-grade chainsaw designed for demanding cutting tasks. This parts manual provides detailed diagrams, part numbers, and ordering information for all components of the Husqvarna 235 chainsaw, including the engine assembly, cutting equipment, fuel system, ignition system, and chassis. Below are key sections for safety, parts identification, assembly diagrams, ordering, and maintenance.
Before handling any parts or performing maintenance, read all safety instructions. Use only genuine Husqvarna replacement parts.
| Warning | Description |
|---|---|
| Personal Protective Equipment (PPE) | Always wear gloves, eye protection, and hearing protection when handling chainsaw parts. |
| Sharp Components | Chain, guide bar, and sprocket are extremely sharp. Handle with care. |
| Fuel System | Work in a well-ventilated area. Ensure fuel tank is empty and carburetor is depressurized. |
| Ignition System | Disconnect the spark plug boot before working on engine or cutting parts. |
| Fasteners | Use correct tools. Adhere to specified torque values to prevent damage. |
Key assemblies: Engine (Cylinder, Piston, Crankshaft), Cutting Equipment (Guide Bar, Saw Chain, Sprocket), Fuel System (Tank, Carburetor, Filter), Ignition (Spark Plug, Coil), Chassis (Crankcase, Handles, Covers).
WARNING! Using non-genuine or incorrect parts may void warranty and cause unsafe operation.
Includes cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets.
| Part Description | Husqvarna Part Number | Notes |
|---|---|---|
| Cylinder Assembly | 503 87 65-01 | Includes cylinder and base gasket |
| Piston Kit | 537 25 40-02 | Includes piston, rings, wrist pin, and circlips |
| Crankshaft | 501 87 54-33 | Complete with integrated crankpin |
| Crankcase Gasket Set | 503 87 71-05 | Set of all engine case gaskets and seals |
| Spark Plug (BRISK) | ZEF 4C-7 | Gap: 0.5 mm (0.020 in) |
CAUTION! Always replace chain and bar together if excessively worn. Mismatched wear causes kickback.
Access OSD via TV MENU or SETUP (DVD). Front Panel: POWER, OPEN/CLOSE, AUTO/DPMS, MUTE.
Fuel System: Fuel Tank, Cap, Filter, Fuel Lines, Carburetor (ZAMA C1M), Primer Bulb. Ignition System: Ignition Coil, Spark Plug Boot, Stop Switch, Wiring Harness.
Picture: BRIGHT, CONTRAST, COLOR, TINT, SHARPNESS, backlight, color temp, noise reduction. Audio: SMART SOUND (PERSONAL, NEWS, MUSIC, THEATRE). Install: Language (ENGLISH default), auto-program channels. DVD: TV display (Wide, Pan Scan), audio options, video settings, password (9999).
Includes front/rear handles, anti-vibration mounts, crankcase halves, side covers, and muffler.
Tip: Inspect anti-vibration mounts regularly. Worn mounts increase vibration and operator fatigue.
Alphabetical index of common parts for quick reference.
| Part Name | Part Number | Qty per Saw |
|---|---|---|
| Air Filter | 503 87 70-01 | 1 |
| Chain Catcher | 501 87 45-25 | 1 |
| Clutch Cover | 537 01 40-11 | 1 |
| Fuel Filter | 501 87 95-01 | 1 |
| Oil Pump | 501 87 46-05 | 1 |
| Throttle Lockout | 501 87 92-33 | 1 |
| Wrist Pin Bearing | 503 87 72-01 | 1 |
Critical steps for engine reassembly and crankcase sealing.
WARNING! Incorrect assembly can lead to engine seizure or catastrophic failure.
Use a calibrated torque wrench. Values in Nm (ft-lbs).
Regular maintenance ensures optimal performance and longevity.
| Component | Every 10 Hours | Every 50 Hours | Every 100 Hours |
|---|---|---|---|
| Air Filter | Clean | Replace | - |
| Spark Plug | Check/Clean | Replace | - |
| Fuel Filter | - | Replace | - |
| Sprocket | Inspect | Replace if worn | - |
| Chain Sharpness | Sharpen as needed | - | - |
| Anti-Vibration Mounts | Inspect | Replace if cracked | - |
| Symptom | Possible Cause | Parts to Check/Replace |
|---|---|---|
| Engine won't start | No spark, fuel issue | Spark plug, ignition coil, fuel filter, carburetor diaphragm kit. |
| Loss of power | Clogged filter, exhaust port carbon | Air filter, fuel filter, muffler spark arrestor. |
| Excessive vibration | Worn mounts, unbalanced clutch | Anti-vibration mounts, clutch drum, crankshaft bearings. |
| Chain oil not flowing | Clogged oil passages, faulty pump | Oil pump, oil pickup filter, oil lines. |
| Chain throws or breaks | Worn sprocket, improper tension | Guide bar, sprocket, saw chain, chain tensioner. |
Service: For technical support and genuine parts, contact Husqvarna at 1-800-487-5962 or visit www.husqvarna.com.