McCulloch 3516 Chainsaw Repair Manual

The McCulloch 3516 is a 35cc gas-powered chainsaw featuring a 16-inch guide bar, automatic oiler, anti-vibration system, and tool-less chain tensioning. This manual provides comprehensive repair, maintenance, and troubleshooting information for owners and technicians. Below are key sections covering safety, specifications, disassembly, engine repair, bar/chain maintenance, carburetion, ignition, and troubleshooting procedures.

1. Safety Precautions 2. Specifications 3. Tools Required 4. Disassembly Procedure 5. Engine Repair 6. Bar & Chain Maintenance 7. Carburetor Adjustment 8. Ignition System 9. Fuel System 10. Reassembly Guide 11. Troubleshooting

Safety Precautions

Always prioritize safety when repairing chainsaws. Key safety components: Chain brake, throttle lockout, rear hand guard, spark arrestor muffler.

Safety Feature	Description
Chain brake	Stops chain rotation instantly upon kickback
Throttle lockout	Prevents accidental throttle engagement
Rear hand guard	Protects right hand from broken chain
Spark arrestor muffler	Reduces fire risk from exhaust sparks
Anti-vibration system	Reduces operator fatigue and improves control
Right-hand guard	Additional protection for cutting hand
Chain catcher	Catches broken chain to prevent injury
Bar tip guard	Prevents contact with bar nose during operation
Stop switch	Immediate engine shutdown
Fuel shutoff valve	Prevents fuel leakage during storage

Specifications

Technical specifications for McCulloch 3516 chainsaw.

Engine Displacement: 35cc 2-stroke gasoline engine.
Guide Bar Length: 16 inches (40cm).
Chain Pitch: 3/8" low-profile.
Chain Gauge: 0.050".
Power Output: 2.1 HP at 9,500 RPM.
Fuel Capacity: 13.5 fl oz (400ml).
Oil Capacity: 8.1 fl oz (240ml).
Weight: 10.8 lbs (4.9 kg) without bar and chain.
Ignition System: Electronic CDI.
Carburetor: Zama C1Q or equivalent.

Tools Required

Essential tools for repair and maintenance.

Socket set (8mm, 10mm, 13mm)
Torx T27 screwdriver for clutch cover
Spark plug wrench (13/16")
Chain breaker and rivet spinner
Compression tester
Multimeter for ignition testing
Carburetor adjustment tool
Feeler gauges (0.020" for spark plug)
Piston stop tool for flywheel removal
Flywheel puller (McCulloch specific)

WARNING! Always use proper tools to avoid damage to components.

Disassembly Procedure

Step-by-step disassembly for major repairs.

Remove bar and chain: Loosen nuts, remove clutch cover, detach chain from bar.
Remove top cover: Remove two screws at rear, lift cover off.
Remove fuel tank: Drain fuel, disconnect fuel line, remove mounting screws.
Remove carburetor: Disconnect throttle linkage, remove mounting nuts.
Remove cylinder cover: Remove four screws, lift cover carefully.
Remove clutch: Use clutch removal tool, turn clockwise to remove.
Remove flywheel: Use flywheel puller, do not pry.
Remove ignition coil: Remove two mounting screws.
Remove oil pump: Remove mounting screws and drive gear.
Separate crankcase halves: Mark alignment, remove all case screws.

CAUTION! Take photos during disassembly for reassembly reference.

Engine Repair

Engine component inspection and repair procedures.

Cylinder and Piston: Inspect for scoring. Acceptable piston clearance: 0.002-0.003". Replace if scored. Crankshaft: Check bearings for smooth rotation. Replace if rough or noisy. Connecting Rod: Check for play at crankpin. Maximum side play: 0.012". Seals: Replace crank seals if leaking (common failure). Compression: Should be 120-150 PSI. Below 100 PSI indicates wear.

Bar & Chain Maintenance

Guide bar and chain maintenance procedures.

Chain sharpening: File at 30° angle, maintain consistent depth gauges.
Bar maintenance: Clean groove, flip bar regularly for even wear.
Chain tension: Proper tension - chain should snap back when pulled from bar.
Sprocket inspection: Replace if teeth are hooked or worn.
Oil flow check: Run at idle, chain should show oil fling.

Tip: Always wear gloves when handling chain.

Carburetor Adjustment

Zama C1Q carburetor adjustment procedure.

Initial settings: L screw 1-1/4 turns out, H screw 1 turn out.
Start engine, warm up for 5 minutes.
Adjust idle: Turn T screw until chain just stops moving.
Adjust low speed: Turn L screw for smoothest acceleration.
Adjust high speed: Turn H screw for maximum RPM (12,500-13,500).
Final idle adjustment: Reset T screw after H/L adjustments.

WARNING! Do not lean out H screw excessively to avoid engine damage.

Ignition System

Testing and replacement of ignition components.

Spark plug: Champion RCJ7Y or equivalent. Gap: 0.020". Coil air gap: 0.010-0.012". Testing: Check for spark with tester. Resistance: Primary 0.5-2.0Ω, Secondary 5-15kΩ. Switch continuity: Should open when stop button pressed.

Fuel System

Fuel system maintenance and repair.

Fuel filter: Replace annually. Fuel lines: Check for cracks, replace if hardened. Tank vent: Clear if plugged. Carburetor kit: Includes diaphragms, gaskets, needle valve. Fuel mix: 40:1 with 2-cycle oil (3.2oz per gallon).

Reassembly Guide

Reassembly in reverse order of disassembly with special notes.

Crankcase assembly: Use sealant on case halves, torque to 10 ft-lbs.
Seal installation: Press seals flush, lubricate lips with grease.
Piston installation: Ring ends must align with pins in groove.
Cylinder installation: Lubricate piston and cylinder with oil.
Flywheel installation: Torque nut to 25 ft-lbs.
Clutch installation: Torque to 15 ft-lbs.
Carburetor: Use new gaskets, connect throttle linkage properly.
Fuel system: Prime carburetor before starting.
Final check: Verify all fasteners tight, controls operate smoothly.

CAUTION! Do not force components during reassembly.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel, or compression	Check spark, fuel delivery, compression (min 100 PSI).
Engine starts then dies	Fuel filter clogged, tank vent blocked	Replace fuel filter, clear tank vent.
Poor acceleration	Carburetor adjustment, air leak	Adjust L screw, check crank seals.
Chain won't oil	Oil pump, lines, or bar hole clogged	Clean oil passages, replace pump if faulty.
Excessive vibration	Clutch balance, mounting loose	Check clutch balance, tighten all mounts.
Overheating	Lean fuel mix, clogged cooling fins	Adjust carburetor rich, clean fins.
Chain won't stop	Brake band worn, mechanism dirty	Replace brake band, clean mechanism.
Loss of power	Exhaust clogged, piston scored	Clean spark arrestor, inspect cylinder.

Reset: After repairs, reset carburetor to factory settings.

Service: For parts: 1-800-521-5103; www.mcculloch.com