Husqvarna Spring Cassette Assembly for 592XP Chainsaw

The Husqvarna 592XP recoil spring cassette assembly is the spring pack inside the starter that rewinds the rope after each pull. When the spring breaks or loses tension, the rope hangs out of the housing or rewinds weakly, and a big-bore saw becomes hard to start.

Why the spring fails

The 592XP is a big felling and bucking saw, and its starter works hard. Letting the rope snap back, pulling it out to the end of its travel, and sawdust inside the starter all wear the recoil spring. A broken spring means the rope stays out, which is a quick way to tear up the starter or the rope.

If the rope doesn't return or returns slowly, check the spring before you replace the whole starter.

Big saws are harder to start than small ones, and the starter on a 592XP gets pulled hard. Keep the starter area clean and free of sawdust, pull the rope straight out, and don't let the handle snap back. Those habits help the spring and rope last longer. If you replace the cassette and the rope still doesn't rewind properly, check the starter pulley and the rope routing.

Replacing the cassette

Remove the starter housing and release any rope tension. Pull out the old cassette, clean the housing, and fit the new one. The cassette design keeps the spring contained, which is safer than handling a loose recoil spring. Wear eye protection anyway.

Re-wind and pre-tension the rope according to the service manual. Find more 592XP starter parts in our chainsaw parts section.