When I say set the saw up, I mean how do you calibrate the carb?
As most of us are aware, the saws 'tune' themselves, but the initial setup is very important.
The system works on a magnet attached to the throttle, which activates one of two magnetic circuit gates, either WOT or idle. It doesn't tune the saw on part throttle, which, if anything, screws up the system, as neither circuit is completed.
If the magnet and gates become mis-aligned problems quickly set in. It was a documented thing on arboristsite where one guys linkage had done this, registering the throttle as 6% open at idle and 94% at WOT, making the saw only partially tune itself.
I set the high rpm by allowing to tune with no load, don't blip the throttle to warm the saw, as rpm is falling as it registers WOT, and rising at idle (causing the machine to register an over-rich at WOT, and over-lean at idle), about 30 seconds of free-load run time should set high rpm.
Allowing the saw to idle for 3 minutes before shutting off the engine causes the calibration to reset to factory settings on a 'safe' mode (over-rich).
I have seen the problems described with the 540 on each one I've handled, but the climbers who use them insist they know better than my advice on how to run said saw...
-Pull the spark screen if you have not already.
-Make sure the air filter is cleaned DAILY.
-Don't let the saw idle for too long between cuts, >2mins turn the saw off.
If your saws have passed the warranty period, get a muffler mod, after 50 hours of run-time, my 560 had .5-1mm of coking on the exhaust port (before it was ported), which is an excessive amount in the given hours, but due to emissions regs, the mufflers are heavily restricted (the outlet is about 8mm diameter, the same size as what people are drilling into the ms150, a saw 1/3 of the cc). Given how tiny the 560's outlet is, I dread to think how small it is on the 540. This also aids the cooling of the saw!
In fact, you can see the coking of the port and where I'd scraped it off with a carb screwdriver. It's also worth noting that when I wasn't using the saw in my employment workplace, I was using aspen, which helps remove any coking!
And as a comparison, the added outlet on the muffler is only an inch diameter.
What oil do you use? As I was running on Stihl hp ultra at that time, if you're running on hp, husky HP, or any Jaso FB oil, you're probably going to have a much worse build up.