Husqvarna 531RS Workshop Manual
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Husqvarna 531RS Workshop Manual

Husqvarna 531RS Workshop Manual

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Workshop manual
531RS 541RS 541RST
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Summary of Contents for Husqvarna 531RS

  • Page 1 Workshop manual 531RS 541RS 541RST English English - 1...

  • Page 2: Workshop Manual

    Workshop Manual 531RS,541RS,541RST 2 - English...

  • Page 3: Introduction And Safety Regulations

    Introduction and safety regulations Introduction and safety regulations 1 Introduction and safety regulations 1.1 General 2. Carry out the sections: Dismantling Cleaning and inspection This Workshop Manual provides a comprehensive Assembly description of how to troubleshoot, repair and test the product.

  • Page 4: General Instructions

    We recommend the use of special tools in order to avoid in death due to asphyxiation or carbon monoxide expensive damage to parts in question and personal poisoning. injury and to provide an efficient repair procedure. Always use Husqvarna’s original: • Spare parts 4 - English...

  • Page 5: Symbols On The Product

    Introduction and safety regulations • Service tools • Accessories 1.10 Symbols on the product The following symbols are moulded into the product casing. Choke control Air purge Refuelling Stop switch 1.11 Symbols in the workshop manu- This symbol indicates a risk of personal injury if instructions are not followed.

  • Page 6: Technical Data

    2 Technical data Displacement Bore Stroke Max. power/rpm / cubic inch Ømm/Øinch mm/inch kW/hp / rpm 541RS/RST 41.5/2.5 40/1.57 33/1.30 1,6/7000 531RS 33.6/2.0 36/1.42 33/1.30 1.2/7000 Compression ratio Spark plug Electrode gap Ignition system mm/inch 541RS/RST 7.5:1 NGK BPMR7A 0.6/0.02...
  • Page 7 Technical data Max speed Idle speed Clutch diameter Engage speed mm/inch 541RS/RST 8570 2500 76/3 3300 531RS 8570 2500 76/3 3300 Drive gear Bevel gear ratio Control disc drive Shaft diameter angle mm/inch Ømm/Øinch 541RS/RST 1:1,4 25.4/1 28/1.10 531RS 1:1,4 25.4/1...

  • Page 8: Service Tools

    Service tools 3 Service tools 8 - English...

  • Page 9: Item Description

    Service tools The tools listed here are service tools intended for use on the brush cutter in question. In addition to these tools, a standard set of hand tools is required. Item Description Used for Article number Driver Removing the drive 510 13 90-01 Piston stop Locking the piston...

  • Page 10: Service Data

    XX mm 2.0 - 3.5 Nm 6.0 - 8.0 Nm 2.0 - 3.5 Nm 7.8 - 11.8 Nm 1.5 ~ 2.0 Nm 4 mm 531RS ** 541RS ** 541RST** 531RS * 541RS * 0.5 - 1.0 Nm 541RST * 3.0 - 5.0 Nm...
  • Page 11 Service data 2.9 - 4.9 Nm 7.9 - 14.7 Nm 6.0 - 8.0 Nm 11.0 ~ 17.0 Nm 17 mm 1.6 - 2.9 Nm 5.0 - 8.0 Nm 12.0 ~ 18.0 Nm 2.5 ~ 4.0 Nm 12 mm English - 11...
  • Page 12 Service data 3.0 - 4.5 Nm 3.0 - 4.5 Nm 3.0 - 4.5 Nm 5.0 - 8.0 Nm 15.0 ~ 22.0 Nm 19 mm 7.0 - 10.0 Nm 2.0 - 3.5 Nm 3.0 - 4.5 Nm 3.0 - 4.5 Nm 5.0 - 8.0 Nm 10.0 - 12.0 Nm 2.0 - 3.5 Nm...
  • Page 13 Service data English - 13...
  • Page 14 Starter 5 Starter 5.1 Dismantling WARNING! Protective glasses should be worn when working on the starter to avoid injury to the eyes if, for some reason, the return spring should fly out. 1. Remove the 4 bolts and lift off the starter. See Figure 1.

  • Page 15: Cleaning And Inspection

    Starter 5.2 Cleaning and inspection Clean and inspect all parts. Worn or damaged parts are replaced with new ones. 5.3 Assembly 1. If the return spring (E) has, despite all the precautions, flown out or if you intend to fit a new spring proceed as follows: 1.

  • Page 16: Replacing The Drive

    Starter 5. Tighten the return spring. Pull out the starter cord completely and slow the starter pulley with your thumb. Lift the starter cord up out of the cut-out on starter pulley. Then turn the starter pulley anti-clock-wise 4 revolutions. Check the spring tension.

  • Page 17: Electric System

    Electric system 6 Electric system 6.1 Dismantling 1. The following components must be dismantled for the ignition system to be accessible: The air filter cover, spark plug and cylinder cover. 2. Unhook the throttle cable from the carburettor. See Figure 1. Fig.
  • Page 18 Electric system 5. Remove both screws (D) that hold the centrifugal clutch. See Figure 3. Lift off the clutch. Note the spacers between the flywheel and the centrifugal clutch. Fig. 3 6. Remove the nut holding the flywheel. Fit puller 502 51 49-02 on the flywheel.

  • Page 19: Checking The Ignition Spark

    Electric system 6.3 Assembly 1. Check that the key way in the flywheel and the key way in the crankshaft are undamaged, as well as the key. Fit the flywheel and centrifugal clutch. Do not forget the flat spacers (E). See Figure 6. NOTE! Turn the clutch so that the arrows (F) that in- dicate the direction of rotation are visible from...
  • Page 20 Electric system 3. Also check that the stop switch is in the start posi- tion. Dismantle the top cover from the cylinder cover. Earth the spark plug on the cylinder and pull sharply on the start handle. See Figure 8. A spark should be seen between the electrodes.
  • Page 21 Electric system 7. Attach the ignition coil to the ignition cable and ensure that the wire is folded along the cable. Slide the contact coil into the spark plug cover. TIP! Lubricate the hole in the spark plug cover so that it is easier to slide in the contact coil.

  • Page 22: Air Filter

    Make sure that the air filter is free of cleaning agent before it is impregnated with air filter oil. Fig. 2 Use Husqvarna’s cleaning agent Active Cleaning no. 505 69 85-70. Impregnate the filter with air filter oil. See Figure 3.
  • Page 23 Fuel tank/Tank venting 8 Fuel tank/Tank venting 8.1 Dismantling Tank venting takes place through the fuel cap and needs to be functional for the engine to work. 1. Empty the fuel tank. 2. Remove the air filter cover. 3. Remove the transparent fuel hose (A) (return hose) from the carburettor.

  • Page 24: Fuel Filter

    Fuel filter 9 Fuel filter 9.1 Dismantling The fuel hose in the tank contains a fuel filter. It is accessible through the fill hole. Pull out the filter using tool 502 50 83-01. See Figure 1. Fig. 1 9.2 Cleaning and inspection If the filter is not too dirty, its surface can be cleaned with a brush.
  • Page 25 Carburettor 10 Carburettor WARNING The fuel used in this product and the fuel vapour are dangerous. They can cause eye and skin irritation, breathing problems and are highly flammable. 10.1 Description The figures in this description do not correspond with the carburetor on the product.
  • Page 26 Carburettor The fuel pumping system (see Figure 3) is composed Negative pressure of the pump cover (1), pump diaphragm (5) and pump body (2). When the crankshaft rotates, pressure fluctuations is produced in piston which makes the pump From fuel diaphragm (5) in the pump chamber move up and down.
  • Page 27 Carburettor 10.4 Dismantling 1. Remove the carburettor cover and the air filter. 2. Close the choke valve and blow off any dirt around the carburettor. 3. Disconnect the throttle cable. 4. Dismantle the fuel hoses from the carburettor and note how they are connected so that the fuel pump works as intended.
  • Page 28 Carburettor 9. Carefully lift up non-return valve (C) using your nails. Clean the valve housing and check that the channels are open. Check that the non return valve’s seals (D) are undamaged by carefully squeezing the short sides together. Replace the valve if necessary.
  • Page 29 Carburettor 13. Press out the needle valve’s seat for replacement. Use a suitable punch Ø 4.5 mm. NOTE! Replace the seat, needle valve and lever arm at the same time. The needle valve’s seat should be pressed in level with the carburettor housing.
  • Page 30 Carburettor 10.6 Assembly 1. Pay attention to the following when the carburettor is assembled in the reverse order to dismantling: Make sure the sealing ring (A) has its wide edge against the carburettor housing. The screen (B) must be clean and undamaged. Fig.
  • Page 31 Carburettor 2. Pressure testing the carburettor - Check that the carburettor is sealed. - Connect the pressure tester no. 531 03 06-23 to the fuel inlet (C) on the carburettor. - Pump up the pressure to 50 kPa. - Lower the carburettor in a vessel with petrol in order to discover any leaks more easily.

  • Page 32: Carburettor Adjustments

    Carburettor 10.7 Carburettor adjustments The carburettor has fixed jets for both the low speed and high speed and cannot be adjusted. The only setting necessary is the adjustment of the idle speed with the adjuster screw. Idle speed: 2500 rpm. Use the tachometer no.
  • Page 33 Carburettor English - 33...
  • Page 34 Throttle 11 Throttle 11.1 Dismantling 1. Remove the bolt (A) that attaches the throttle to the handle. Be careful not to lose the nut. Remove the throttle and remove bolts (B) and (C). Carefully separate the two halves of the throttle. See Figure 1. Fig.
  • Page 35 Throttle 11.3 Start throttle speed The start throttle speed can be adjusted using screw (G) 1. Start the engine and let it idle. 2. Press down the start throttle lock (C). 3. When the start throttle speed is too low (below 4000 rpm), screw the adjuster screw (G) clockwise until the cutting equipment starts to rotate.

  • Page 36: Centrifugal Clutch

    Centrifugal clutch 12 Centrifugal clutch 12.1 Dismantling the clutch 1. Remove the cover over the air filter. Separate the short-circuit cables. Disconnect the throttle cable from the carburettor. Remove the 4 screws holding the clutch cover against the fan housing cover. Lift off the entire assembly.
  • Page 37 Centrifugal clutch 12.3 Assembly Connect the clutch shoes together with the spring. Bolt the clutch on the flywheel. Do not forget the washers (A). Note the rotation arrows (B) on the clutch shoes. Fig. 5 12.4 Dismantling the clutch drum 1.
  • Page 38 Centrifugal clutch 4. Dismantle the circlip using circlip pliers. Heat the clutch case to approx. 120°C using a hot air gun. Knock the edge of the cover against a wooden block so the ballbearing falls out or use a hammer and punch.
  • Page 39 Centrifugal clutch English - 39...

  • Page 40: Angle Gear

    Angle gear 13 Angle gear 13.1 Dismantling the bevel gear 1. Remove the cutting equipment and guard. 2. If the brush cutter is equiped with narrow clamp: Remove the clamp screws (A) and the clamp (B). Remove bolts (C and D). Fig.
  • Page 41 Angle gear 4. Remove the circlip (A) on the output shaft. Remove the circlip (B) on the input shaft. Remove the lubricant top-up plug (C). Remove the venting plug (D). See Figure 3. Fig. 3 5. Heat the entire angle gear using a hot air gun to approx.
  • Page 42 Angle gear 13.3 Assemble the bevel gear 1. Start assembling the bevel gear with the output shaft. Place the cogwheel on the shaft. Insert both ball bearings. Use a hot air gun to heat the gear housing to approx. 140°C. Fig.
  • Page 43 Angle gear Fit the circlip for the ball bearing on the output shaft. Fit the sealing ring with the scraping edge facing inwards. Use a suitable punch so that the ring is pushed straight into place without turning. Fit the circlip (B) for the ball bearings on the input shaft.

  • Page 44: Cylinder And Piston

    Cylinder and piston 14 Cylinder and piston 14.1 Dismantling 1. Dismantle the following components to make the cylinder accessible: Starter all covers muffler with heat guard plate against the cylinder (the heat shield under the muffler does not need dismantling) spark plug.

  • Page 45: Faults And Causes

    Cylinder and piston 14.2 Cleaning and inspection After dismantling, clean the individual components: 1. Scrape carbon deposits from the top of the piston. 2. Scrape carbon deposits from the cylinder’s combus- tion chamber. 3. Scrape carbon deposits from the cylinder’s exhaust port.
  • Page 46 Mixing ratio: 1:50 (2%). If Husqvarna two-stroke oil is not available another good quality two-stroke oil can be used. Mixing ratio: 1:33 (3%) or 1:25 (4%).
  • Page 47 Cylinder and piston Piston damage caused by a too high engine speed Typical damage from too high engine speed is ruptured piston ring/piston rings, broken circlip on the gudgeon pin, faulty bearings or that the guide pin for the piston ring has become loose.
  • Page 48 Cylinder and piston 4. Failure of the crankshaft bearing or on the connecting rod bearing is usually caused by a too high engine speed, resulting in the bearing being overloaded or overheating. This in turn can cause the bearing rollers or ball to glide instead of rotate, which can cause the roller or ball retainer to break.
  • Page 49 Cylinder and piston Air filter incorrectly fitted. Fit the filter correctly. Air filter damaged or miss- Fit a new air filter. ing. 3. Larger, softer particles that penetrate into the engine cause damage to the piston skirt under the piston ring as the illustration shows.

  • Page 50: Wear Tolerance

    Cylinder and piston Piston ring burnt in its Carefully loosen the groove. piston rings and clean the groove well before refitting. Carbon deposits in the groove impair the important heat transfer between the piston and cylinder. NOTE! Be careful with the lower edge of the piston ring groove.
  • Page 51 Cylinder and piston Piston ring groove Max. 1.6 mm. Clean the groove before checking the measurement. See Figure 19. Fig. 19 Piston ring play Max. 0.15 mm. Clean the groove before checking the measurement. See Figure 20. Fig. 20 14.5 Assembly 1.

  • Page 52: Leakage Testing

    Cylinder and piston 4. Inspect the distance piece for crack formation or other damage that may result in leakage, which in turn can cause uneven idling and starting difficulties. 5. Assemble the remaining parts in the reverse order as set out for dismantling. See respective sections in the manual.
  • Page 53 Cylinder and piston 3. Remove the muffler cover. Loosen the 2 muffler screws that hold the muffler and press the rubber sheet between the muffler and the cylinder from the underside. Tighten the two screws. Fig. 26 4. Remove the spark plug and screw the pressure test connection 503 84 40-02 to the nipple.

  • Page 54: Crankshaft And Crankcase

    Crankshaft and crankcase 15 Crankshaft and crankcase 15.1 Dismantling 1. Dismantle all components so that only the crankcase and crankshaft remain. See the respective sections for detailed information if necessary. Remove the key for the flywheel. Dismantle the 4 screws holding the crankcase halves together.
  • Page 55 Crankshaft and crankcase 5. Knock the crankcase half against a wooden block to make the the ballbearing fall out. Fig. 5 6. Dismantle the sealing rings from the crankcase halves. Use a suitable punch (504 91 28-00) or sleeve and knock out the sealing rings with the help of a hammer.
  • Page 56 2. Inspect the small end of the connecting rod. If seizure marks or discolouration are found in the bearing track the crankshaft must be replaced. Fig. 10 3. Check the crank bearing. The connecting rod shall not have any radial play (up and down). It should, however, have axial play, in order to ensure good lubrication of the crank bearing among other things.
  • Page 57 3. Fit the crankshaft in the crankcase half on the flywheel side. Lubricate the stub axle with a few drops of oil and carefully slide the crankshaft into the bearing. Check that the 3 guide bushings are in position in the crankcase half. Fig.

  • Page 58: General Troubleshooting

    Troubleshooting 16 Troubleshooting 16.1 General troubleshooting Does not idle Stop screw for the throttle not working The different faults which may occur on the chainsaw Fuel filter blocked are divided into four groups. Within each group The fuel hose blocked possible operating faults are listed to the left while the Air in fuel ducts probable fault alternatives are listed to the right.
  • Page 59 Troubleshooting Poor performance Fuel filter blocked at high speed The fuel hose blocked Air in fuel ducts Incorrect/poor fuel Vacuum pulse leakage Vacuum pulse duct blocked Loose screw(s) on the pump cover Faulty pump diaphragm The needle valve is faulty Carburettor is not fitted correctly Needle valve’s lever arm is damaged...
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541rs541rst

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