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Sounds like the chain brake is locked. On the front of the saw, in front of where you would put your left hand on the handle is another piece. Its probably plastic. With the saw off, take your hand, place your thumb on the front handle, your 4 fingers on top of the paddle & pull the paddle back toward the front handle until it clicks, thus releasing the chain brake & freeing the chain.
I have read and re-read your problem and I keep going back to the "spongy" feel, which strongly suggests air in the lines.
Make sure you have no brake fluid leaking anywhere, especially in the "tee" where your brake line splits to feed both calipers. Even the smallest leak will allow air to be introduced.
If you are absolutely certain that you have no air in the lines, the most likely problem is one or both caliper pistons are worn and allowing fluid to leak by under pressure.
I recommend replacing the calipers- If you rebuild them, the slightest mistake honing the cylinders will result in your needing to replace anyway.
HD parts can be very expensive, so I suggest you check out Tedds in Newburgh, NY: They have a huge selection and prices are reasonable. You will need to google it because this site keeps dropping me when I try and post the link- world wide web dot vtwinmfg dot com If you have ever watched American Chopper (love 'em or hate 'em), this is where the Tuthills get allot of their parts. They will send you a HUGE catalog for free.
Good Luck! FYI my first street HD was a 1980 Sportster.
The chainbrake should be activated when starting the chain saw. Activate the chain brakeby pushing the front hand guard forwards.b>Cold engine Start position, 1: Set the start/stop switch in the choke position by pulling thered control outward - upward.Decompression valve: Press the valve to reduce the pressure in the cylinder and makestarting easier. Once the machine has started the valve will automaticallyreturn to its original setting.Air purge: Press the air purge diaphragm repeatedly until fuel fills thediaphragm (at least 6 times). The diaphragm need not be completely filled.Grip the front handle with yourleft hand. Hold the chain saw on the ground by placing your right foot throughthe rear handle.Pull the starter handle, 4: Pull the starter handle with your right hand and pull out thestarter cord slowly until you feel a resistance (as the starter pawls engage)then pull firmly and rapidly until the engine fires.Push down the red choke control: As soon as the engine fires which can be heard through a"puff" sound, push down on the red choke control.Pull the starter handle (6): Keep on pulling the cord powerfully until the engine starts.
You will need to release the brake by applying a very heavy screwdriver to the + shaped part of the brake coupling. Check the action of the brake handle and duplicate it at the the +. Hope this helps!
Your OM (all manufacturers) says to engage the chain brake prior to starting. It is the safest way to start your saw.
I start my saws on the ground (like the OM recommends), right toe in rear handle, wide stance, left hand on front handle with the chain brake disengaged. The saw I used first (Pioneer 1980±) has no chain brake.
I now have a Mac 110 (top handle) that is very awkward to start on the ground. I engage the brake on it before I attempt a start. Whatever method you use Please exercise great caution.
If you have more questions or need additional help please reply below and I will get back to you. HTH & Good Luck. Lou Thank You for using FixYa.
along with warning that the e-brake is engaged, it's also a waning light that something is wrong with the brake system. however, it may be a defective switch on the e-brake handle. i would have a break check done. also chech the fluid level.
I was just fighting this on husqvarna. I re-set the brake by fitting the cover tilted to the front, jiggling the chain brake handle to engage it with the brake sprocket. Once engaged, push handle back to unbraked position while bearing down on the cover. You'll feel the click as it locks back to unbraked position.
I have a 340 Huskuvarna but experienced the same problem. It must be a common Husky problem because when I called their tech support the lady told me exactly what to do. So your first solution is to call tech support and they will talk you thru it. Basically though... after you have your bar and chain on. Put you brake handle forward (brake ON postion). Put your cover on, bar nuts on loosely and get the brake part engaged with the cover plate. It doesn't look right at this point. The cover will be crooked/cocked with the front part on and the back part over the clutch off. Then push down on the back part as you pull the brake handle into the off position.
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