Husqvarna 440 e II barely starts, dies when given gas.

Happster

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Apr 27, 2026
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Dunstable, MA, USA
Hey all. Just went through the entire saw and I'm still right where I started. I can get it to start, but it only idles for a few seconds and almost always dies when I try to hit the gas. If I feather it, I can get it to stay running for a few more seconds, but that's it. What I've done:

Complete breakdown, new base gaskets, crank seals, checked piston and ring, cylinder, all were fine. New carb, spark plug, primer bulb and fuel lines. Checked the intake boot, in very good condition, no dry rot or cracks. New fuel filter.

It is getting spark, has compression, fuel is priming beautifully.

So I'm just stumped. Interestingly, before tearing it down, I suspected base gaskets and/or crank seals were air leaking so I tried to see if the crankcase would hold about 7 ft lbs of pressure with my pressure gun. I fabricated a plate for the exhaust port with a piece of rubber inner tube for a gasket and bolted that down, made a similar contraption for the intake port that II held by hand and tried to put pressure through the plug. The needle did not even move...no pressure building up at all. So I assumed it was the base gaskets and/or seals, tore her down and replaced them all. Tried the pressure test afterwards and still no pressure at all. Where could the air possibly go? I see side plates on the jug with special torx screws, but those don't appear to be obviously leaking.

What else can I try? Much appreciated.
 
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