Jonsered 2165 build

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sled_22

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I thought I’d share this with everyone. I picked up this 2165 from a fellow member of AS. Very pleasant transaction. I wanted a saw for a complete rebuild. It was pretty rough. Bearings were shot piston was fried. Cylinder wasn’t not bad but decided I wanted to build it to a 2171. Picked up a 372xp top end.
 

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Completely disassembled. Found bearing were cooked. Crank is still in good shape after clean. No vertical play. Biggest pain for disassembly was the clutch. Had to grind an old socket down to make a three prong wrench. Spent about 6 hours in the parts washer and prepped the case for paint. Not a perfect match. It is close as you can see the test on the one clutch cover. Everything is cleaned and setting out now.Waiting for new skf bearings in the mail.
I’m putting a hyway 372 top end in it. Also picked up a hyway jungle muffler. This will basically be a play/work saw.
new seals, carb kit, fuel and oil lines and filters, all new bearings, new brake handle, you all get the drift.
I plan on freezing the crankshaft and heating the bearings to install. Has anyone rebuilt these and found there’s any need to set the bearings in the case with a spacer any anything? Or just drop them straight into the case to the seat in the case? More to come when I get the rest of the parts.
 

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Cool saws aren't they, I had good luck tweaking the closed port 48mm top ends from throw away 2165 & 365 specials.
Yeah they are. I like the esthetics of jonsered for an older saw. The handling and power fit me well. They aren’t my primary work saws but I will say my friends and family quit working when I get the 2095 out for the big stuff when we’re cutting wood. Now that’s a fun saw to run. Otherwise it’s hard to beat the ms462 for all around work saw being light and powerful.
 
Got some work done this weekend. Froze the crankshaft and heated bearings then froze the whole works to install in heated cases. Went pretty well. Also got the muffler and intake installed while freezing parts. Also installed a new pull rope and checked the recoil spring. It’s always fun to rewind this suckers.
what does everyone do to center the crank shaft. Mine was a little off, had to tap one side. Then it went too far it seems. So I tapped it back a little until centered.
 

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Clutch cover is finished.
 

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Piston was mounted. Plenty of 2 stroke lube. Make sure the wrist pins point up. Lube the cylinder then carefully set the cylinder. Don’t forget a new gasket before the cylinder. Before I pushed the piston all the way in I poured some more 2 stroke lube down the spark plug hole and worked it around to cost the cylinder walls.
after that I started mounting the carb plate and tank. Ran new fuel and impulse lines. I put a new fuel filter in the tank and mounted the tank/handle. I also had to put the kill wires in.
hopefully tomorrow my new seal for the pto shows up and it can be finished.
 

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Closer to start up. Carb cleaned. Crank seal installed. No issues this time. Everything pooped right together. I think that last seal was jimmied from the git go. Hopefully tomorrow I’ll have more time to finish.
 
Pics
 

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Be careful using tygon for the impulse it don't take the heat well. I have had them get loose and even melt back when I used to use it.
Thanks for the heads up. I was just trying to use it up. I might just switch it now before finishing the build.
much appreciated
 
I put the saw through some idling heat cycles then some sawing heat cycles throughout the weekend and couldn’t be happier how it turned out. I have a few cosmetic things to finish off and then it’ll be put into the firewood lineup. I can’t wait to drop it into some bigger wood when I get the rings fully seated.
 

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Got the new recoil cover and decal added. Looks good!
 

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