Jonsered 535 Chainsaw Manual

The Jonsered 535 is a professional-grade chainsaw designed for demanding forestry and arborist work. It features a high-performance engine, robust construction, advanced safety systems, and ergonomic design for extended use. Below are key sections covering safety, features, assembly, operation, maintenance, troubleshooting, and specifications.

Features at a Glance

Key components: High-torque 2-stroke engine, Anti-Vibration System (AVS), Quick-release air filter, Combined choke/stop control, Inertia-activated chain brake, Side-mounted chain tensioner.

Safety Instructions

Read and understand all instructions before use. Always wear proper PPE.

1. Personal Protective Equipment (PPE): Always wear chainsaw chaps, safety helmet with face shield and hearing protection, gloves, and steel-toe boots.
2. Work Area Safety: Clear area of bystanders, especially children. Ensure secure footing and no trip hazards.
3. Fuel Safety: Refuel in well-ventilated area, engine off and cool. Use correct fuel/oil mix (see specifications).
4. Kickback Awareness: Understand kickback zone (upper quadrant of bar tip). Use reduced-kickback chain and maintain sharp chain.
5. Carrying & Transport: Engage chain brake, carry with bar pointing rearward. Use scabbard/guard.

WARNING! Failure to follow safety instructions can result in serious injury or death. Never operate a chainsaw while tired or under the influence.

Assembly & Preparation

Unpack and inspect contents. Assemble on a clean, flat surface.

1. Attach Guide Bar & Chain: Loosen bar nuts. Fit bar over studs. Place chain over sprocket and onto bar groove, ensuring cutting teeth face forward on top. Tighten bar nuts finger-tight.
2. Tension Chain: Use side-mounted tensioner screw to adjust until chain fits snugly against bar but can be pulled around by hand. Retighten bar nuts securely.
3. Fill Fuel & Oil: Use correct 2-stroke mix (50:1 with Jonsered oil recommended). Fill chain oil tank with proper bar & chain oil.
4. Check Controls: Ensure throttle trigger, throttle lockout, and chain brake function correctly.

CAUTION! Always check chain tension when cold. A loose chain can derail; an overtightened chain can damage the saw and bar.

Specifications

• Model: Jonsered 535
• Engine Type: 2-stroke, single cylinder, air-cooled
• Displacement: 53.5 cc
• Power Output: Professional grade, high torque
• Fuel/Oil Mix Ratio: 50:1 (using Jonsered 2-stroke oil)
• Recommended Fuel: Minimum 90 octane unleaded gasoline
• Idle Speed: 2,700 - 3,300 rpm (factory set)
• Maximum Power Speed: Approx. 9,500 rpm
• Sound Power Level (LWA): Typically 112 dB(A) - Wear hearing protection!
• Vibration Levels (Front/Rear Handle): Low due to AVS system
• Warranty: Refer to local dealer for professional use warranty terms.

Controls and Components

Familiarize yourself with all controls before starting the engine.

Main Controls:

• Front Handle: Includes throttle trigger and throttle lockout (must be depressed to engage trigger).
• Rear Handle: Main grip with stop switch.
• Combined Choke/Stop Control: Lever for starting (choke) and stopping (push past stop).
• Chain Brake Lever (Front Hand Guard): Manually engage by pushing forward. Inertia-activated during kickback.
• Master Control Lever: (If equipped) Combines choke, stop, and warm start settings.
• Decompression Valve: Reduces compression for easier starting (press before pulling cord).
• Fuel & Oil Caps: Clearly marked.
• Side Chain Tensioner: Screw for adjusting chain tension with bar nuts loose.

Starting & Stopping Procedure

Follow these steps precisely for safe starting.

Cold Start:

1. Place saw on firm, level ground. Engage chain brake.
2. Press decompression valve (if equipped).
3. Set master control lever to choke position (full up).
4. Pump primer bulb (if equipped) 5-7 times until fuel is visible.
5. Place your right foot through the rear handle for stability. Grip front handle with left hand, pull starter handle with right hand. Pull cord sharply 3-5 times until engine 'pops'.
6. Move control lever to half-throttle (fast idle) position.
7. Pull starter cord again until engine starts. Saw will run at high idle.
8. Briefly blip the throttle to disengage fast idle. Release chain brake before cutting.

Warm Start: Set control lever to half-throttle position only. Do not use choke.

Stopping: Release throttle, allow engine to idle. Push the stop switch to "0" or push the master control lever to the stop position.

Operation & Cutting Techniques

Use proper stance and grip. Let the saw do the work.

1. Basic Stance: Feet shoulder-width apart, firm footing. Hold saw securely with both hands, thumbs wrapped around handles.
2. Felling (Cutting Down a Tree): Plan escape path. Make notch cut (1/3 tree diameter) on fell side. Make felling cut from opposite side, leaving hinge wood. Retreat along planned path.
3. Limbing: Work from trunk base upward. Keep trunk between you and the bar. Beware of spring-loaded branches.
4. Bucking (Cutting Logs): Support log off ground. Cut from top to avoid pinching. For logs under tension, cut compression side first.
5. Avoiding Kickback: Do not cut with bar tip. Maintain firm grip. Keep chain sharp and properly tensioned. Use low-kickback chain.

WARNING! Never operate the saw above shoulder height or with one hand. Be constantly aware of the bar tip location.

Maintenance Schedule

Regular maintenance ensures performance, safety, and longevity.

Chain & Bar Care

A sharp, well-lubricated chain is essential for safe and efficient cutting.

1. Sharpening: Use correct round file size (typically 4.0mm or 4.8mm). Maintain original filing angles (usually 30°). File all cutters to equal length. File depth gauges (rakers) with a flat file and gauge.
2. Lubrication: Ensure oil tank is filled with proper bar & chain oil. Check oil flow by running saw at idle near a light-colored surface; a line of oil should be visible.
3. Bar Maintenance: Regularly clean bar groove. Flip bar weekly to ensure even wear. File down any burrs on bar rails.
4. Chain Replacement: Replace chain when cutters are worn down to the line, damaged, or after repeated sharpening.

Tip: Soak a new chain in oil before first use. Never run the saw without bar oil.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

1. Short-term (1-2 months): Run the saw dry of fuel (let it stall). Drain bar oil tank. Clean entire saw. Store in a dry place.
2. Long-term (Seasonal): Perform all short-term steps. Remove spark plug, add a teaspoon of engine oil into cylinder, pull starter cord slowly to coat internals, reinstall plug. Store chain separately in oil.

CAUTION! Never store a chainsaw with fuel in the tank for more than 30 days. Modern fuel can degrade and damage carburetor components.

Troubleshooting

For Service: Contact an authorized Jonsered service dealer for repairs involving engine disassembly, carburetor adjustment, or electrical issues.