Husqvarna 359 Rebuild Kit Tips (5 Pro Mods For More Power)

Husqvarna 359 Rebuild Kit Tips (5 Pro Mods for More Power)

Investing in a Husqvarna 359 rebuild kit can seem daunting initially, but trust me, the long-term savings and performance gains are well worth it. A well-maintained chainsaw is a safe and efficient chainsaw, and a rebuilt Husqvarna 359 can often outperform a brand-new, lower-quality saw. I’ve seen firsthand how these modifications can breathe new life into an old workhorse, transforming it into a reliable and powerful tool for years to come. This guide will walk you through five pro modifications you can implement while rebuilding your Husqvarna 359 to unlock its full potential.

Understanding the Husqvarna 359 and Its Potential

The Husqvarna 359 is a legendary chainsaw, known for its robust design, ease of maintenance, and impressive power for its size. It’s a favorite among loggers, farmers, and serious homeowners who need a reliable saw for demanding tasks. However, like any machine, the 359’s performance can degrade over time due to wear and tear. A rebuild is an excellent opportunity to not only restore the saw to its original condition but also to enhance its performance with carefully selected modifications.

I remember one time, I was helping a friend clear some land for a new barn. His old 359 was struggling, bogging down in even moderately sized logs. After a rebuild with some of these modifications, it was like a completely different saw – cutting through hardwoods with ease.

Preparing for the Rebuild: Essential Tools and Safety Precautions

Before diving into the rebuild, it’s crucial to have the right tools and to prioritize safety. Working on a chainsaw involves sharp objects, flammable liquids, and potentially dangerous situations.

Essential Tools:

Husqvarna 359 Rebuild Kit: Includes piston, cylinder, rings, wrist pin, circlips, gaskets, and seals.
Piston Stop Tool: Prevents the crankshaft from turning while removing the clutch and flywheel.
Impact Wrench: Speeds up the removal of stubborn nuts and bolts.
Torque Wrench: Ensures proper tightening of critical components.
Feeler Gauges: For checking piston ring end gap.
Cylinder Hone: For deglazing the cylinder wall (if reusing the original cylinder).
Assembly Lube: For lubricating moving parts during reassembly.
Carburetor Adjustment Tool: For fine-tuning the carburetor after the rebuild.
Cleaning Supplies: Carburetor cleaner, degreaser, and rags.
Protective Gear: Safety glasses, gloves, and hearing protection.

Safety Precautions:

Disconnect the Spark Plug: Prevent accidental starting during the rebuild.
Work in a Well-Ventilated Area: Avoid breathing in fumes from solvents and cleaners.
Wear Safety Glasses: Protect your eyes from debris.
Wear Gloves: Protect your hands from sharp edges and chemicals.
Follow the Manufacturer’s Instructions: Refer to the Husqvarna 359 service manual for detailed instructions and torque specifications.

Takeaway: Proper preparation is key to a successful and safe rebuild. Gather your tools, prioritize safety, and familiarize yourself with the service manual.

Pro Mod #1: High-Performance Cylinder and Piston Kit

The heart of any engine is the cylinder and piston. Upgrading to a high-performance kit is arguably the most significant modification you can make to your Husqvarna 359. These kits often feature improved porting, larger displacement, and enhanced cooling.

Benefits of a High-Performance Cylinder and Piston Kit:

Increased Power Output: Improved porting allows for better airflow, resulting in more efficient combustion and increased horsepower. I’ve seen dyno tests showing gains of 10-15% with these kits.
Enhanced Torque: Larger displacement provides more torque, allowing the saw to handle larger logs and tougher wood species with greater ease.
Improved Cooling: Better cooling fins and material composition help dissipate heat more effectively, preventing overheating and extending engine life.
Durability: Many high-performance kits are made from stronger materials, offering increased resistance to wear and tear.

Selecting the Right Kit:

Consider the Manufacturer: Choose reputable brands like Meteor, Hyway, or Farmertec. Read reviews and compare specifications.
Check the Displacement: Some kits increase the displacement slightly, while others offer more significant gains. Match the displacement to your needs and skill level.
Examine the Porting: Look for kits with well-designed and precisely machined ports.
Read Reviews: See what other users have to say about the kit’s performance and durability.

Installation Tips:

Clean the Crankcase Thoroughly: Remove any debris or old gasket material before installing the new cylinder.
Use Assembly Lube: Lubricate the piston, cylinder walls, and wrist pin with assembly lube to prevent scoring during initial startup.
Torque to Specification: Use a torque wrench to tighten the cylinder bolts to the manufacturer’s specified torque.
Check Piston Ring End Gap: Use feeler gauges to ensure the piston ring end gap is within the specified range. Adjust if necessary.

Real-World Example: A small logging operation in Oregon upgraded their fleet of Husqvarna 359s with high-performance cylinder and piston kits. They reported a significant increase in productivity, with each saw cutting approximately 20% more wood per day. They also noted a reduction in downtime due to overheating issues.

Takeaway: A high-performance cylinder and piston kit is a game-changer for the Husqvarna 359. Choose a reputable brand, follow installation instructions carefully, and enjoy the increased power and performance.

Pro Mod #2: Modified Muffler for Improved Exhaust Flow

The muffler plays a crucial role in controlling exhaust noise and directing exhaust gases away from the operator. However, the stock muffler on the Husqvarna 359 can be restrictive, limiting the engine’s ability to breathe freely. Modifying the muffler can significantly improve exhaust flow, resulting in increased horsepower and torque.

Benefits of a Modified Muffler:

Increased Horsepower: Improved exhaust flow reduces backpressure, allowing the engine to breathe more efficiently and produce more power.
Enhanced Torque: Reduced backpressure also improves torque, especially in the mid-range.
Improved Throttle Response: The engine will respond more quickly to throttle inputs.
Reduced Engine Temperature: Better exhaust flow can help reduce engine temperature.

Methods of Muffler Modification:

Drilling Additional Holes: Drill additional holes in the muffler to increase exhaust flow. Be careful not to weaken the muffler structure.
Removing Baffles: Removing internal baffles can significantly improve exhaust flow. However, this will also increase noise levels.
Installing a Dual Port Muffler: A dual port muffler provides two exhaust outlets, further reducing backpressure.
Using an Aftermarket Muffler: Several aftermarket mufflers are designed specifically for the Husqvarna 359 and offer improved flow and performance.

Considerations:

Noise Levels: Muffler modifications will increase noise levels. Consider the impact on your neighbors and the environment.
Spark Arrestor: Ensure that your modified muffler still includes a functional spark arrestor to prevent wildfires.
Carburetor Adjustment: Modifying the muffler will likely require adjusting the carburetor to compensate for the increased airflow.

DIY Modification Tips:

Start Small: Begin with small modifications and gradually increase the exhaust flow until you achieve the desired performance.
Use Quality Tools: Use sharp drill bits and a steady hand to avoid damaging the muffler.
Wear Eye and Ear Protection: Protect your eyes and ears from debris and noise.
Check for Leaks: After modifying the muffler, check for exhaust leaks.

Case Study: A firewood producer in Maine modified the mufflers on their Husqvarna 359s by drilling additional holes. They reported a noticeable increase in power and a reduction in engine overheating, allowing them to process more firewood per day. However, they also noted an increase in noise levels and the need for more frequent carburetor adjustments.

Takeaway: Modifying the muffler is a relatively simple and inexpensive way to improve the performance of your Husqvarna 359. However, be mindful of noise levels, spark arrestor requirements, and the need for carburetor adjustments.

Pro Mod #3: Carburetor Optimization and Tuning

The carburetor is responsible for mixing air and fuel in the correct proportions for combustion. A properly tuned carburetor is essential for optimal engine performance, fuel efficiency, and emissions control. After rebuilding your Husqvarna 359 and making other modifications, it’s crucial to optimize and tune the carburetor.

Understanding Carburetor Components:

High-Speed Jet (H): Controls the fuel mixture at high engine speeds.
Low-Speed Jet (L): Controls the fuel mixture at low engine speeds and idle.
Idle Speed Screw (T): Adjusts the engine’s idle speed.

Carburetor Tuning Procedure:

Warm Up the Engine: Allow the engine to warm up to operating temperature before making any adjustments.
Adjust the Low-Speed Jet (L): Turn the low-speed jet screw clockwise until the engine starts to bog down. Then, turn it counterclockwise until the engine runs smoothly and accelerates cleanly.
Adjust the High-Speed Jet (H): With the engine running at full throttle, adjust the high-speed jet screw until the engine runs smoothly and produces maximum power. Avoid running the engine too lean, as this can cause damage.
Adjust the Idle Speed Screw (T): Adjust the idle speed screw until the engine idles smoothly without stalling.
Fine-Tune: Make small adjustments to the low-speed and high-speed jets as needed to achieve optimal performance.

Tips for Carburetor Tuning:

Use a Tachometer: A tachometer can help you accurately measure the engine’s RPM and ensure that you’re not running it too lean or too rich.
Listen to the Engine: Pay attention to the engine’s sound. A lean engine will often sound high-pitched and raspy, while a rich engine will sound muffled and sluggish.
Check the Spark Plug: The spark plug can provide valuable information about the engine’s fuel mixture. A light tan color indicates a properly tuned engine, while a black or sooty plug indicates a rich mixture, and a white or gray plug indicates a lean mixture.
Make Small Adjustments: Small adjustments to the carburetor can make a big difference in performance. Avoid making large, sudden changes.

Upgrading the Carburetor:

Consider an Aftermarket Carburetor: Several aftermarket carburetors are designed specifically for the Husqvarna 359 and offer improved performance and adjustability.
Install a Velocity Stack: A velocity stack can improve airflow into the carburetor, resulting in increased horsepower and torque.

Personal Experience: I once spent hours trying to diagnose a Husqvarna 359 that was running poorly. After replacing the spark plug, air filter, and fuel filter, I finally realized that the carburetor was the problem. A thorough cleaning and tuning of the carburetor made a world of difference, restoring the saw to its original performance.

Takeaway: Optimizing and tuning the carburetor is essential for maximizing the performance and efficiency of your Husqvarna 359. Use a tachometer, listen to the engine, check the spark plug, and make small adjustments to achieve optimal results.

Pro Mod #4: Upgraded Ignition System

The ignition system is responsible for generating the spark that ignites the air-fuel mixture in the cylinder. An upgraded ignition system can provide a stronger, more consistent spark, resulting in improved engine performance, starting reliability, and fuel efficiency.

Benefits of an Upgraded Ignition System:

Improved Starting: A stronger spark makes it easier to start the engine, especially in cold weather.
Increased Horsepower: A more consistent spark ensures more complete combustion, resulting in increased horsepower and torque.
Improved Fuel Efficiency: More complete combustion also improves fuel efficiency.
Reduced Emissions: More complete combustion reduces emissions.
Increased Reliability: Upgraded ignition systems are often more durable and reliable than the stock systems.

Types of Upgraded Ignition Systems:

High-Performance Ignition Coils: These coils provide a stronger spark than the stock coils.
Electronic Ignition Modules: These modules replace the traditional points and condenser system with a more reliable electronic system.
Adjustable Timing Advance: Some upgraded ignition systems allow you to adjust the timing advance, which can further optimize engine performance.

Installation Tips:

Follow the Manufacturer’s Instructions: Carefully follow the manufacturer’s instructions when installing an upgraded ignition system.
Use the Correct Spark Plug: Use the spark plug recommended by the manufacturer of the ignition system.
Check the Air Gap: Ensure that the air gap between the ignition coil and the flywheel is properly adjusted.
Use a Timing Light: A timing light can help you accurately set the timing advance.

Considerations:

Cost: Upgraded ignition systems can be expensive.
Complexity: Some upgraded ignition systems are more complex to install than others.
Compatibility: Ensure that the upgraded ignition system is compatible with your Husqvarna 359.

Example: A tree service company in California upgraded the ignition systems on their Husqvarna 359s to improve starting reliability in cold weather. They reported a significant reduction in starting problems and an increase in overall engine performance.

Takeaway: An upgraded ignition system can provide a significant boost to the performance, reliability, and fuel efficiency of your Husqvarna 359. Choose a system that is compatible with your saw and carefully follow the installation instructions.

Pro Mod #5: Optimization of Air Intake

Optimizing the air intake system is crucial for ensuring that the engine receives a sufficient and clean supply of air. A restricted or dirty air filter can significantly reduce engine performance and fuel efficiency. Modifications to the air intake can improve airflow, leading to increased horsepower and torque.

Benefits of Optimizing Air Intake:

Increased Horsepower: Improved airflow allows the engine to breathe more efficiently, resulting in increased horsepower and torque.
Improved Fuel Efficiency: A clean air filter and optimized air intake system improve fuel efficiency.
Extended Engine Life: A clean air filter prevents dirt and debris from entering the engine, extending engine life.
Improved Throttle Response: The engine will respond more quickly to throttle inputs.

Methods of Optimizing Air Intake:

Use a High-Flow Air Filter: A high-flow air filter allows more air to pass through than a standard air filter.
Modify the Air Filter Housing: Modifying the air filter housing can improve airflow into the carburetor.
Install a Velocity Stack: A velocity stack can improve airflow into the carburetor, resulting in increased horsepower and torque.
Ensure Proper Air Filter Maintenance: Regularly clean or replace the air filter to ensure optimal airflow.

Air Filter Maintenance Tips:

Clean the Air Filter Regularly: Clean the air filter after each use or more frequently if you’re working in dusty conditions.
Use Compressed Air: Use compressed air to blow out the air filter.
Wash the Air Filter: Wash the air filter with soap and water.
Oil the Air Filter: Oil the air filter with air filter oil.
Replace the Air Filter: Replace the air filter when it becomes damaged or worn.

DIY Modification Tips:

Be Careful When Modifying the Air Filter Housing: Be careful not to damage the air filter housing when modifying it.
Use Quality Tools: Use quality tools to avoid damaging the air filter housing.
Wear Eye Protection: Wear eye protection when working with compressed air.

Real-World Application: I was recently working on a logging project in a particularly dusty area. After noticing a significant drop in performance on my Husqvarna 359, I checked the air filter and found it completely clogged with dust. After cleaning the air filter, the saw’s performance was immediately restored. This experience underscored the importance of regular air filter maintenance.

Takeaway: Optimizing the air intake system is crucial for maximizing the performance, fuel efficiency, and longevity of your Husqvarna 359. Use a high-flow air filter, modify the air filter housing, install a velocity stack, and ensure proper air filter maintenance.

Post-Rebuild Care and Maintenance

Rebuilding your Husqvarna 359 with these modifications is a significant investment, and proper post-rebuild care and maintenance are essential for ensuring its longevity and performance.

Break-In Period:

Run the Engine at Varying Speeds: Avoid running the engine at full throttle for extended periods during the break-in period.
Use a Rich Fuel Mixture: Use a slightly richer fuel mixture during the break-in period to provide extra lubrication.
Check for Leaks: Regularly check for fuel and oil leaks.
Monitor Engine Temperature: Monitor the engine temperature and avoid overheating.

Regular Maintenance:

Clean the Air Filter Regularly: Clean the air filter after each use or more frequently if you’re working in dusty conditions.
Sharpen the Chain Regularly: Sharpen the chain regularly to maintain optimal cutting performance.
Lubricate the Chain Regularly: Lubricate the chain regularly to reduce wear and tear.
Check the Spark Plug Regularly: Check the spark plug regularly and replace it as needed.
Clean the Cylinder Fins Regularly: Clean the cylinder fins regularly to prevent overheating.
Inspect the Fuel Lines Regularly: Inspect the fuel lines regularly for cracks and leaks.
Store the Saw Properly: Store the saw in a dry, clean place when not in use.

Troubleshooting:

Refer to the Service Manual: Refer to the Husqvarna 359 service manual for troubleshooting tips.
Check the Fuel System: Check the fuel system for problems such as a clogged fuel filter or a faulty fuel pump.
Check the Ignition System: Check the ignition system for problems such as a faulty spark plug or a bad ignition coil.
Check the Compression: Check the compression to ensure that the engine is sealing properly.

Long-Term Storage:

Drain the Fuel Tank: Drain the fuel tank before storing the saw for an extended period.
Remove the Spark Plug: Remove the spark plug and pour a small amount of oil into the cylinder.
Store the Saw in a Dry Place: Store the saw in a dry, clean place.

Final Thoughts:

By following these pro modification tips and implementing a consistent maintenance schedule, you can significantly enhance the power and longevity of your Husqvarna 359. Remember, a well-maintained chainsaw is a safe and efficient chainsaw. The investment in these modifications will pay off in increased productivity, reduced downtime, and years of reliable service. I’ve seen firsthand the transformative power of these upgrades, and I’m confident that you will too. Happy cutting!

Husqvarna 359 Rebuild Kit Tips (5 Pro Mods for More Power)