Husqvarna 555 Workshop Manual
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Husqvarna 555 Workshop Manual

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Workshop manual
555, 556, 560 XP, 560 XPG
English
1540 - 001 -

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Summary of Contents for Husqvarna 555

  • Page 1 Workshop manual 555, 556, 560 XP, 560 XPG English 1540 - 001 -...

  • Page 2: Table Of Contents

    Contents 1 Introduction 7 Repair instructions 1.1 Document description..........3 7.1 Product overview for repair instructions....13 1.2 Target group............3 7.2 To clean and examine the product parts....15 1.3 Revisions..............3 7.3 Chain brake............15 1.4 Safety..............3 7.4 Chain catcher............19 1.5 Servicing tools............3 7.5 Muffler..............

  • Page 3: Introduction

    WARNING: All personnel that repair or do servicing on the product must read and understand the safety instructions in this workshop manual. 1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1540 - 001 - Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions • Wear protective gloves when you replace the crankshaft bearings. The crankcase halves are hot, Warnings, cautions and notes are used to point out risk of burn injuries. specially important parts of the manual. • Make sure that the chain brake is engaged when you remove the pressure spring on the chain brake.

  • Page 5: Cutting Equipment Safety

    Chain oil. If your product has this symbol it has heated handles. yyyywwxxxx The rating plate shows se- rial number xxxx. yyyy is the production year and ww is the production week. Note: Other symbols/decals on the product refer to certification requirements for some markets.

  • Page 6: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule Maintenance Before After 100 After 40 h operation Clean the external surfaces. After each operation. Clean the muffler, exhaust pipe and engine from dirt and unwanted lubricant. After each operation. Make sure that the saw chain does not move at idle speed.

  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ■ Lubricate with two-stroke oil. ● Lubricate with grease. ▲ Lubricate with chain oil. 12 – 14 Nm 13mm 18 – 20 Nm 16mm 8 – 10 Nm T27 1,5 – 2 Nm T20 1 –...
  • Page 8 7 – 9 Nm T27 1 – 2 Nm 3 – 4 Nm T27 3 – 4 Nm T27 9 – 11 Nm T27 22 – 25 Nm 13mm 3 – 4 Nm T27 9 – 11 Nm T27 6 – 8 Nm T27 3 –...

  • Page 9: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1540 - 001 - Servicing tools - 9...
  • Page 10 Item Description Article num- Piston stop To lock the crankshaft. 575 29 36-01 Exhaust seal To seal the exhaust port. 575 29 81-01 Inlet seal To seal the inlet system. 574 71 14-01 Seal plugs for inlet To seal the inlet pipes. 574 70 12-01 Pressure gauge To do a pressure test.
  • Page 11 Item Description Article num- Piston assembly kit To assemble the piston. 502 50 70-01 Piston pin tool To remove the piston pin. 597 91 80-01 Crankshaft assembly tool To assemble the crankshaft. 590 89 08-01 Installation tool Guide ring for protective cap. 596 99 03-03 Engine diagnostic tool To do troubleshooting of the product.

  • Page 12: Function Overview

    For best results and performance use Husqvarna two- stroke oil. If Husqvarna two-stroke oil is not available, use a two- stroke oil of good quality for aircooled engines. Speak to your servicing dealer to select the correct oil. 6.2.2.3 To mix gasoline and two-stroke oil...

  • Page 13: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 1540 - 001 - Repair instructions - 13...
  • Page 14 1. Front handguard 10. Throttle trigger 2. Front handle 11. Fuel tank 3. Muffler 12. Carburetor 4. Cylinder cover 13. Cylinder and piston 5. Air filter 14. Lubrication system 6. Starter unit 15. Heated handle switch 7. Start/stop switch 16. Centrifugal clutch and clutch drum 8.

  • Page 15: To Clean And Examine The Product Parts

    7.3 Chain brake 19. Clutch cover 20. Generator 7.3.1 To disassemble the chain brake 21. Thermostat and heating element 22. Ignition system WARNING: Use approved eye protection. The 23. Flywheel recoil spring can eject and cause injuries. 24. Crankcase 25. Crankshaft 1.
  • Page 16 3. Carefully tighten the clutch housing in a vise. Use 6. Remove the screw (D), the chain tensioner cover the handguard to release the chain brake. (E), the adjustment screw (F), the shaft (G), the washer (H) and the O-ring (J). Remove the screw (K) and the chain guide (L).
  • Page 17 7.3.2 To clean and examine the chain brake 3. Attach the chain guide (L) and the screw (K). Attach the O-ring (J), the washer (H), the shaft (G), the 1. Carefully clean and examine all parts of the chain adjustment screw (F), the chain tensioner (E) and brake.
  • Page 18 5. Put the clutch cover in a vise. Compress the chain 7. Use the front handguard to tighten the chain brake brake spring with a wide screwdriver and push it spring. Connect the front handguard to the chain down with your thumb. brake mechanism and turn clockwise to release the chain brake.

  • Page 19: Chain Catcher

    7.4 Chain catcher 3. Remove the muffler (C), the gasket (D) and the heat deflector (E). 7.4.1 To replace the chain catcher WARNING: You must always replace a worn chain catcher. Always use original spare parts. 1. Remove the clutch cover. 2.

  • Page 20: Start/Stop Switch

    7.5.3 To assemble the muffler 7. Tighten the 2 crankcase screws (G) to the correct Servicing data on page 7 . torque. Refer to 1. Attach the spark arrester screen (A) with the screw (B). 8. Attach the cylinder cover. 7.6 Start/stop switch 7.6.1 To remove and install the start/stop switch 1.

  • Page 21: Handles

    7.7 Handles 7.6.2 To do a function test of the start/stop switch 1. Clean the surfaces where you will measure the 7.7.1 To remove and install the front handle resistance. 1. Loosen the screw in the vibration damping system. 2. Connect a multimeter to the blue cable and the cylinder to measure the resistance.
  • Page 22 7.7.2 To remove and install the heated front handle 3. Remove the 2 screws. 1. Remove the 2 screws and the cover for the heated front handle. 4. Remove the 2 screws. 2. Remove the switch (A) from the contact plate (B). Disconnect the wire (C) from the connection plate.
  • Page 23 5. Remove the heated front handle from the product. 7. Loosen the screw to the vibration damping system. 8. Loosen the deflection limiter. 6. Install in the opposite sequence. 7.7.3 To remove and install the heated rear handle To remove 1.
  • Page 24 9. Lift the saw carefully and pull down the hoses 10. Remove the screw and pull out the heated rear through and the throttle wire down through the handle and pull out the cables. carburetor bottom plate. Make sure that you understand how the cables are attached.

  • Page 25: Starter

    7.7.4 To disassemble and assemble the rear 4. Remove the throttle wire and the throttle trigger. handle 1. Remove the screw and the handle cover. If the To remove and product has heated handles, refer to install the heated rear handle on page 23 . 5.
  • Page 26 3. Pull out the starter rope approximately 30 cm/12 in. 5. Remove the screw and washer (D). and put it into the notch in the starter pulley. 4. Let the starter pulley rotate slowly counterclockwise to release the tension of the recoil spring. 6.
  • Page 27 7.8.3 To assemble the starter unit 3. Pull the starter rope through the hole in the starter housing. WARNING: Use approved eye protection. The recoil spring can eject and cause injuries. 4. Pull the starter rope through the starter rope handle and make a knot.

  • Page 28: Ignition System

    7.9.2 To examine the spark plug CAUTION: Use resistor spark plugs to prevent problems during operation and permanent damage to the ignition system. Only use spark plugs recommended by Husqvarna, refer to the operator's manual. 7.9 Ignition system • Examine the spark plug if the engine is low on power, is not easy to start or does not operate 7.9.1 To do a spark test...
  • Page 29 • If the spark plug is dirty, clean it and make sure that 6. Pull out the spark plug cable. Technical data the electrode gap is correct, refer to on page 65 . • Replace the spark plug if it is necessary. 7.9.3 To remove the ignition system 1.

  • Page 30: Flywheel

    7.9.4 To install the ignition system 5. Attach the spark plug cable to the cooling air conductor. 1. Connect the ignition module. 2. Install the ignition module and the 2 screws. 6. Put an air gap gauge between the ignition module and the flywheel.
  • Page 31 4. Remove the spark plug and put a piston stop in the 9. Attach the socket of the flywheel puller tool (H) on spark plug hole. the crankshaft. 10. Use a wrench (J) to lock the outer socket of the flywheel puller tool.

  • Page 32: Centrifugal Clutch

    5. Make sure that you install the 2 springs in the 4. Remove the spark plug and put a piston stop in the correct position, as shown in the illustration. spark plug hole. 6. Put the air gap gauge between the flywheel and the ignition module.
  • Page 33 6. Remove the clutch (A), the clutch drum (B), the 7.11.2 To clean and examine the centrifugal clutch bearing (C), the bearing (D) and the worm gear (E). 1. Clean and examine the clutch shoe springs (A), the clutch hub (B) and the clutch shoes (C) carefully. Replace damaged parts.

  • Page 34: Lubrication System

    7.12 Lubrication system 7.12.2 To clean and examine the lubrication system 7.12.1 To disassemble and assemble the 1. Clean and examine all parts carefully. Replace lubrication system damaged parts. Always use the original spare parts. WARNING: The saw chain can break if the 2.

  • Page 35: Carburetor

    7.14 Carburetor give a fuel/air mixture that can be ignited by the ignition spark. 7.14.1 Carburetor design WARNING: The fuel used in the product has the following hazardous properties: The fluid and its vapour are poisonous, can cause skin irritation and are highly inflammable.
  • Page 36 Air is sucked in through an aperture in the throttle valve 3. Turn the knob and remove the air filter from the air and a small amount of fuel is supplied through the filter holder. diffuser jet (D). In part throttle mode, the throttle valve (I) is partly open 4.
  • Page 37 7. Remove the air filter holder. 11. Disconnect the throttle wire (E). 8. Remove the return hose (A) and the suction hose (B) from the air purge bulb. 12. Remove the fuel hose (F). 13. Remove the 2 screws and the bracket. 9.
  • Page 38 15. Push down the lever to release the carburetor. 17. Disconnect the cable connectors. 18. Install in the opposite sequence. 16. Remove the carburetor. 38 - Repair instructions 1540 - 001 -...
  • Page 39 7.14.4 Carburetor components 1540 - 001 - Repair instructions - 39...
  • Page 40 41 . 4. Use the Engine Diagnostic Tool to examine the 10. On 555 and 556: Attach the 4 screws and washers ™ Servicing tools on page 9 .

  • Page 41: Fuel Tank

    7.14.8 To adjust the metering lever 7.14.10 Troubleshooting leakage The distance between the metering lever and the gasket Fault Cause surface of the carburetor housing must be 0.55 mm. Leakage in the diffuser jets The needle Adjust the distance if it is more or less than 0.55 mm. valve •...
  • Page 42 9. Remove the screw of the vibration damping system. 12. Remove the tank unit. 10. Loosen the deflection limiter. CAUTION: Be careful not to cause damage to the hoses when you remove the tank unit. 13. Install in the opposite sequence. 11.
  • Page 43 7.15.2 To replace the fuel filter 3. Use a fuel filter hook to pull out the fuel hose and the Servicing tools on page 9 . fuel filter. Refer to 1. Remove the fuel tank cap. 2. Use a fuel filter hook to pull out the fuel hose and the Servicing tools on page 9 fuel filter.
  • Page 44 6. Attach the new fuel hose to the fuel tank as the 3. Connect the pressure tester to the tank valve (A). illustration shows. 7. Attach the fuel filter to the new fuel hose. 8. Install the fuel tank cap. 9.

  • Page 45: Vibration Damping System

    7.16 Vibration damping system 7.17 Generator 7.16.1 To disassemble and assemble the vibration 7.17.1 To remove the generator damping system To remove and 1. Remove the fuel tank. Refer to install the fuel tank on page 41 . 1. Use a Torx to remove the vibration damping unit from the cylinder.
  • Page 46 5. Install the cables. 8. Attach the deflection limiter. 9. Tighten the 2 screws in the front vibration damping unit. 10. Tighten the 2 screws (A) in the rear vibration damping unit. a) Attach the cable (A) between the generator and the heating element.

  • Page 47: Cylinder And Piston

    12. Install the air filter holder and the carburetor. Refer 5. Remove the 4 screws and lift the cylinder. Remove To remove and install the carburetor on page 36 . the sleeves for the 4 screws. 13. Install the air filter. 14.
  • Page 48 8. Use pliers to remove the snap ring from the pin. 4. Clean the bottom of the cylinder and the bottom of Keep your thumb adjacent to the snap ring to make the crankcase. Remove all gasket particles and dirt sure that the snap ring do not eject.
  • Page 49 7.18.4 To examine the inlet manifold 7.18.5 To examine the piston 1. Remove the 4 screws and remove the inlet manifold 1. Make sure that the piston pin bearing is not from the cylinder. damaged. 2. Make sure that the piston pin does not have damages on the running surface for the bearing.
  • Page 50 7.18.7 To examine the piston rings 5. Carefully attach the piston ring on the piston. Make sure that you do not cause damage to the piston ring 1. Examine the piston rings for damage. or the piston. 2. Replace damaged piston rings. 6.

  • Page 51: Crankshaft And Crankcase

    9. Assemble the remaining parts in the opposite 7. Connect the pressure tester to the spark plug Servicing tools on page 9 . sequence to how they were disassembled. adapter. Refer to 7.18.9 To do a pressure test of the cylinder 1.
  • Page 52 To disassemble the 10. Remove the starter. Refer to 3. Use a screwdriver to remove the seal ring. starter unit on page 25 . 11. Remove the air filter and the air filter holder. Refer to To remove and install the air filter on page 34 . To remove Remove the start/stop switch.
  • Page 53 7. Use the press tool to push the new seal ring to the 4. Remove the deflection limiter (D). Servicing tools on page 9 correct position. Refer to 8. Remove the seal ring tool and the guide ring. 9. Install in the opposite sequence. 7.19.3 To disassemble the crankshaft and the crankcase 1.
  • Page 54 6. Remove the crankcase half on the clutch side from 4. Put the nut (C) on the crankshaft. Tighten the nut to the crankshaft. Use the crankcase disassemble tool. the correct torque. Servicing tools on page 9 . Refer to 7.
  • Page 55 7.19.5 To clean and examine the crankshaft and 7.19.6 To install the crankcase bearings crankcase WARNING: Use protective gloves. The crankcase halves are hot. CAUTION: Make sure that dirt and unwanted particles do not go into the crankcase and into the bearings.

  • Page 56: Guide Bar Bolts

    4. Use the crankcase assemble tool to push the 7. Assemble the carburetor bottom plate to the Servicing crankcase to the correct position. Refer to crankcase and tighten the 4 screws (D) to the tools on page 9 . Servicing data on page 7 . correct torque.

  • Page 57: Thermostat And Heating Element

    7.21 Thermostat and heating element 7.20.2 To install the guide bar bolts 1. Attach a steel wire to the thread of a guide bar bolt. 7.21.1 To remove and install the thermostat and heating element The models 560 XP and 560 XPG has a thermostat and heating element.
  • Page 58 7. Remove the switch (A) from the connection plate 8. Disconnect the wires and pull out the wires from the (B). Disconnect the wire (C) from the connection handle. Be careful when you pull the wire through plate. Disconnect the handle wire (D) from the the handle.

  • Page 59: To Repair A Damaged Thread

    11. Disconnect the thermostat wires. Disconnect the generator wires. Remove the heating elements. 12. Install in the opposite sequence. 7.22 To repair a damaged thread A damaged thread can be repaired with a thread insert. Note: For aluminum threads, use helicoil and metric screws.

  • Page 60: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting 3. Measure the resistance between point (B1) and (D1). The resistance for heating element must be You can do the troubleshooting procedure with most 0,8-1,0 Ω. components attached to the product. Tools necessary for the troubleshooting procedure is: 4.

  • Page 61: Troubleshooting Diagram

    8.7 Troubleshooting diagram Starter rope Perform “Cleaning and inspec- Defect Change part or entire tion” of starter housing does not retract starter if needed. starter housing (see separate instr.) Sticking starter Change part or entire Defect starter housing housing starter if needed. Check air gap between Start rope stuck Change part if needed.

  • Page 62: Engine Running Issue

    Cylinder Does the Crankcase gaskets engine Crankcase start ? Issue still remains? Perform a visual inspection of interface between Contact your Husqvarna carburettor and intake rubber for leakage. Local Sales Company for advice. 62 - Troubleshooting 1540 - 001 -...

  • Page 63: Engine Running Issue

    Check cables and connectors for wear. Product OK Check torque on ignition coil screws. Check the ground wire. Issue still remains? Contact your Husqvarna Local Sales Company for advice Leakage Check function of decompression valve (if equipped). Check mounting/interface intake rubber and carburettor.

  • Page 64: Ignition System Diagnostic Flow Chart

    8.10 Ignition System Diagnostic Flow Chart Perform visual inspection of unit. Inspect spark plug wire, boot connections. Repair/replace any problem items Install new, properly gapped, manufacturer specified spark plug. Stop switch must be in run position. Perform Spark Test (See separate instructions). End Test Is a strong Does engine...

  • Page 65: Technical Data

    9 Technical data 9.1 Technical data Husqvarna 555 Husqvarna 556 Husqvarna 560 XP Engine Cylinder displacement, cm 59.8 59.8 59.8 Idle speed, rpm 2800 2800 2800 Maximum engine power acc. to ISO 8893, kW/hp @ 3.1/4.2 @ 9600 3.1/4.2 @ 9600 3.5/4.8 @ 9600...
  • Page 66 Husqvarna 560 XPG Husqvarna 562 XP Husqvarna 562 XPG Engine Cylinder displacement, cm 59.8 59.8 59.8 Idle speed, rpm 2800 2800 2800 Maximum engine power acc. to ISO 8893, kW/hp @ 3.5/4.8 @ 9600 3.5/4.8 @ 9600 3.5/4.8 @ 9600...
  • Page 67 1540 - 001 - Technical data - 67...
  • Page 68 1142464-26 2020-11-05...

This manual is also suitable for:

556560 xp560 xpg

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