10/22/2026
Sometimes I receive a chainsaw project in a box or one of those 5-gallon pails. Somebody started troubleshooting and gave up.
In the worst cases, the saw has been left without a spark plug or carburetor, exposing the inside of the engine to the elements. Many of those can’t be saved.
I keep a completely seized MS 290 crankshaft, with the piston still attached, on my workbench to show people what happens when moisture gets inside an engine that sits unused for a long, long time. The bearings are so stiff that the entire crankshaft, connecting rod, and piston assembly is rigid.
The owner of this saw got lucky. The spark plug had been left out—and was completely missing—and the box had definitely been stored somewhere without humidity control. But the engine wasn’t seized.
As a precaution, I squirted a little two-stroke oil into the combustion chamber before moving the piston to give the top end some lubrication. I didn’t know yet that the piston was scored, but this is a good habit whenever I encounter an engine that hasn’t been started in a long time and may have been exposed to moisture.
As with some other saws you’ve seen on my page, compression came in at a reasonable 140 psi. But I noticed the side screws for the muffler brace were missing. Those holes lead directly into the oil tank, so the bar oil likely would’ve leaked out over time.
Predictably, the oil tank was empty.
I poured the fuel into a glass jar to inspect it, and it didn’t look like a proper 50:1 mix.
Anyway, those missing screws made me check the actual muffler screws, which were loose. My spidey senses were definitely tingling at this point, so I removed the muffler to inspect the piston.
Yep, it was scored.
I explained to the customer that the Husqvarna 359 is a very good professional saw and definitely worth a top-end rebuild.
I also warned him that if the bearings weren’t smooth, rebuilding the bottom end probably wouldn’t make financial sense given the saw’s overall value. I don’t want a customer spending more on repairs than the saw is worth unless there’s some sentimental value involved.
This one came from a yard sale. No sentimental value at all.
I also showed him the modified aftermarket muffler, which should give it a little more power. Kind of cool.
He was on board with a rebuild as long as it wasn’t too costly. I explained that the only way to know was to remove and inspect the piston and check the bearings. He told me to proceed.
Well, it turned out the piston had only minor heat scoring and was completely clean on the intake side.
A good habit when I’m unsure whether the crank seals need replacing is to remove the clutch before removing the cylinder. It’s much easier while the cylinder is still installed because I can use compression, a piston stop, or rope inserted into the combustion chamber to provide resistance while loosening the clutch.
Once the cylinder is off, getting that resistance becomes a lot more of a hassle.
Anyway, after removing the clutch, flywheel, cylinder, and piston, I could finally check the bearings for grinding, resistance, or other signs of damage. Of course, I thoroughly cleaned and lubricated them first.
Smooth as silk. The bottom end is good to go.
I dug around on my shelf and found a Husqvarna 357 XP cylinder kit. For those who don’t know, the 357 and 359 share the same chassis, so there’s a choice of cylinders when doing a rebuild. Although the 357 has a 1 mm smaller bore, its cylinder and piston design favors high-RPM horsepower. The 359 has the bigger bore, but it isn’t quite as much of a hot rod.
In my earlier years of repairing chainsaws, I thought the bigger bore was the advantage. Since then, I’ve learned that the 357 is actually the hotter saw.
So I’m going to build this one back as a 357 XP. It won’t have the crank stuffers that come in the 357, but it should still be a more enjoyable saw to use.
Curious about what crank stuffers do? Ask in the comments, and I’ll explain it there.
Since there’s evidence of heat scoring, leaking crank seals are one possible explanation for the overheating. I’m going to rebuild the top end, then check the crank seals for leaks.