Husqvarna 531RB Workshop Manual
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Husqvarna 531RB Workshop Manual

Husqvarna 531RB Workshop Manual

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Workshop manual
541RB, 531RB
English
935 - 001 -

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Summary of Contents for Husqvarna 531RB

  • Page 1 Workshop manual 541RB, 531RB English 935 - 001 -...

  • Page 2: Table Of Contents

    Contents 1 Introduction 1.1 Document description..........3 1.2 Target group............3 1.3 Revisions..............3 1.4 Safety..............3 1.5 Servicing tools............3 2 Safety 2.1 Safety definitions............4 2.2 General safety instructions........4 2.3 Special safety instructions........4 2.4 Symbols on the product......... 4 3 Prepare and do servicing on the product 3.1 Maintenance schedule...........

  • 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. 935 - 001 - Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions Use a protective helmet in locations where objects can fall on you. Use approved Warnings, cautions and notes are used to point out hearing protection. Use approved eye specially important parts of the manual. protection. WARNING: Used if there is a risk of injury or death for the operator or bystanders if the instructions in the manual are not obeyed.

  • Page 5: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule X = The instructions are given in this workshop manual. * = General maintenance. The instructions are not given O = Refer to the operator's manual for instructions. in this manual. Maintenance Each 6 Daily...

  • Page 6: Servicing Data

    4 Servicing data 4.1 Servicing data Smart start starter 7.3 - 8.3 Nm 2.9 - 4.4 Nm 2.9 - 4.4 Nm 4.9 - 7.8 Nm 2.9 - 5.0 Nm 12 - 18 Nm 10 - 12 Nm 12 mm 2.9 - 3.9 Nm 2.0 - 3.5 Nm 11 - 17 Nm 6.9 - 9.8 Nm...
  • Page 7 5 - 8 Nm 15 - 22 Nm 19 mm 10 mm 1.5 - 2.5 Nm 3 - 4.5 Nm 14 mm 2.0 - 3.5 Nm ▲ ▲ ▲ ▲ ▲ 5 - 8 Nm 5 - 8 Nm 935 - 001 - Servicing data - 7...
  • Page 8 1.0 - 2.0 Nm 1.6 - 2.9 Nm 3 mm 1.6 - 2.9 Nm 4 mm 2.0 - 2.9 Nm 1.6 - 2.9 Nm 3 mm 8 - Servicing data 935 - 001 -...
  • Page 9 1.5 - 2.9 Nm 3.0 - 5.0 Nm 10 mm 1.5 - 2.9 Nm 4.9 - 6.9 Nm 4 mm 15 - 20 Nm 17 mm 6.9 - 8.8 Nm 10 mm 1.6 - 2.9 Nm 6.9 - 8.8 Nm 10 mm 15 - 20 Nm 17 mm...

  • Page 10: Servicing Tools

    5 Servicing tools 10 - Servicing tools 935 - 001 -...
  • Page 11 Item Description Use to Article number Piston stop Lock the piston 522 43 18-01 Hex key Remove screws Torx T27 Remove and attach torx screws 502 71 27-03 Piston assembly kit Assemble the piston 502 50 70-01 Removal tool Remove the starter pawl assembly 510 13 90-01 Sleeve for crankshaft Protection for the seal ring...

  • Page 12: Function Overview

    7. Make sure that there is no leak in the fuel tank. • If Husqvarna two-stroke oil is not available, you may use another two-stroke oil of good quality that is intended for air cooled engines.Contact your dealer when you select an oil.

  • Page 13: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 935 - 001 - Repair instructions- 13...

  • Page 14: To Clean And Examine The Product Parts

    1. Starter 3. Put your thumb on the starter pulley. 2. Muffler 4. Put the starter rope in the groove in the starter 3. Air filter and air filter holder pulley. 4. Carburetor 5. Let the starter pulley rotate rearward until the spring 5.
  • Page 15 7.3.2 To disassemble the Smart start starter 6. Remove the screw (A). WARNING: Use protective glasses to prevent injury to the eyes if the recoil spring ejects. 1. Remove the 4 screws. Remove the starter. 2. Pull out the starter rope approximately 30 cm. 3.
  • Page 16 9. Remove the recoil spring from the starter pulley. 3. Put the recoil spring in the groove of the starter housing. Push down the recoil spring with your thumb on the inner side of the starter housing. Move your thumb around the edge of the starter pulley and push down the recoil spring turn after turn.
  • Page 17 6. Put the starter pulley (C) in the starter housing. c) Turn the starter pulley counterclockwise 4 Install the washer (B) and the screw (A). Install the revolutions. plastic cover (D). d) Pull out the starter rope fully and turn the starter pulley a minimum of a half revolution more.
  • Page 18 3. Attach the recoil spring in the groove in the starter 5. Put the starter rope through the opening in the pulley. starter housing. 6. Put the starter pulley (D) on the axle of the starter housing. Make sure that the recoil spring (F) is in the groove (G) in the axle.
  • Page 19 7. Put the starter rope through the starter rope handle. 9. Install the starter on the product. Hold the starter in Make a small knot on the starter rope and pull the position and tighten the 4 screws. knot into the handle. 8.

  • Page 20: Muffler

    7.5 Air filter b) Replace the starter pawl assembly if it is damaged. 7.5.1 To remove and install the air filter 5. Install the starter pawl assembly in the opposite 1. Turn the engine around its axle to get access to the sequence.

  • Page 21: Carburetor

    5. Make sure that the filter is dry before you assemble the air filter again. 7.5.3 To apply oil to the air filter CAUTION: Always use Husqvarna special air- filter oil. Do not use other types of oil. 1. Fuel inlet 2.
  • Page 22 The fuel goes into the carburetor through the fuel inlet and down with the throttle valve and adjusts the fuel (1). The fuel valve (2) controls the fuel flow to the flow. carburetor. The fuel is filtered through the fuel inlet screen (3) before it goes into the float chamber (7).
  • Page 23 7.6.3.2 Part throttle position 7.6.4 Gravity fuel supply The fuel tank is installed above the carburetor. Gravity causes the fuel to go from the fuel tank to the carburetor. The fuel valve (B) is installed between the fuel tank and the carburetor and stops the fuel. The gravity fuel supply limits the product from tilted operation.
  • Page 24 7.6.5 Overview of the carburetor 1. Top cap 10. Axle 2. Piston valve 11. Lever arm 3. Spring 12. Needle valve 4. Needle valve 13. Fuel jet 5. Hose 14. Idle adjustment screw 6. Screw 15. Nut 7. Float chamber housing 16.
  • Page 25 19. Screws 4. Open the clamp and remove the fuel hose from the carburetor. 20. Adapter 21. Screws 22. Washers 23. Fuel valve 24. Gasket 25. Fuel drain screw 26. O-ring 27. Choke lever screw 7.6.6 To disassemble and assemble the carburetor CAUTION: Before you do maintenance on the engine, the fuel valve must be closed.
  • Page 26 6. Loosen the top cap (F). Remove the piston valve 10. Remove the axle (P), the lever arm (Q), needle (G), the throttle wire (H), the spring (I) and the valve (R) and the fuel jet (S). needle valve (J). 11.
  • Page 27 7.6.7 To clean and examine the carburetor 7.6.8 To adjust fuel flow to the carburetor To disassemble 1. Clean the needle valve. 1. Disassemble the carburetor, refer to and assemble the carburetor on page 25 . 2. Examine the lever arm and the needle valve. Replace damaged parts.

  • Page 28: Centrifugal Clutch

    7.7 Centrifugal clutch • Make sure that the throttle wire is parallel with the flexible shaft. If the throttle wire is twisted, make the throttle wire straight. 7.7.1 To remove the centrifugal clutch • If the shaft is bent, the play of the wire is changed. 1.
  • Page 29 3. Remove the 2 screws (A) and the muffler cover (B). 7. Remove the 2 screws (G). Remove the 2 washers Remove the screws (C and D) and the cylinder (I). Remove the centrifugal clutch (H). Remove the 2 cover (E). washers (J).

  • Page 30: Ignition System

    7.7.4 To remove and install the clutch drum 7.7.5 To examine the clutch drum To remove the 1. Do the neccessary steps in 1. Examine the clutch drum for wear. Replace the centrifugal clutch on page 28 to remove the clutch clutch drum if it is worn or damaged.
  • Page 31 • If the spark plug is dirty, clean it and make sure that 7.8.4 To examine the spark plug cable Technical data the electrode gap is correct, refer to If there is no spark when you do a spark test of the on page 60 .
  • Page 32 5. Put the end of the cable against the stop of the 9. Push the cable into the spark plug cap. Servicing tools on page 10 . assembly pliers, refer to Then close the pliers to make the new hole. 10.
  • Page 33 7.8.5 To disassemble and assemble the ignition 3. Remove the 2 screws (A) and remove the muffler cover (B). Remove the screws (C and D) and system remove the cylinder cover (E). 1. Pull up the knob and remove the drive shaft tube. 2.
  • Page 34 6. Remove the 2 screws (F) and remove the ignition 9. Remove the 2 screws (G) that hold the centrifugal module from the clutch drum assembly. Replace the clutch (H). Remove the centrifugal clutch. Remove ignition module, if it is necessary. the 2 washers (I) between the screws and the centrifugal clutch.

  • Page 35: Cylinder And Piston

    7.8.6 To examine the ignition system 9. Remove the cylinder base gasket. Make sure that no dirt goes in the crankcase. Put a cloth on the snap 1. Examine the clutch and the flywheel for wear or rings of the wrist pin piston. damages.
  • Page 36 11. Push the wrist pin from the piston with a piston pin 13. Remove the piston rings, if it is necessary. rod. 7.9.2 To clean the cylinder and piston CAUTION: Clean carefully. The soft aluminum parts are easily damaged. • Remove the carbon deposits from these parts: 12.
  • Page 37 • Clean the piston ring groove. • Measure the piston ring play (B). Replace the piston ring if the piston ring play is larger than 0.15 mm. 7.9.3 To examine the cylinder • Put the piston ring in the cylinder and measure the •...
  • Page 38 7.9.5 To assemble the cylinder and piston 6. Put a new cylinder base gasket on the crankcase. 1. Carefully put the piston ring on the piston. Make sure that you do not cause damage to the piston ring or the piston. 2.
  • Page 39 10. Assemble the remaining parts of the cylinder and 3. Loosen, but do not remove, the 2 screws that hold piston in the opposite sequence to how they were the carburetor. Put a rubber sheet between the To disassemble the cylinder disassembled.

  • Page 40: Crankshaft And Crankcase

    7.10 Crankshaft and crankcase 6. Attach the pressure tester to the pressure test plug. 7.10.1 To disassemble the crankshaft and crankcase 1. Pull up the knob and remove the drive shaft tube. 7. Increase the pressure to 0.8 bar and wait for 30 2.
  • Page 41 3. Remove the fuel hose from the carburetor. 13. Remove the screw and remove the plate. 14. Remove the nut and the washer. To disassemble the 4. Remove the starter. Refer to standard starter on page 14 . To replace the 5.
  • Page 42 15. Remove the crankcase from the frame. 17. Remove the screw (A) and remove the heat shield (B). Remove the 4 screws (C). 18. Disassemble the crankcase halves. 16. Remove the 4 screws and remove the support plate. 42 - Repair instructions 935 - 001 -...
  • Page 43 19. Use a screwdriver or equivalent to remove the seal 22. Increase the temperature of the crankcase halves to ring from the crankcase halves. 120ºC with a hot air gun. CAUTION: Remove the seal rings carefully. The crankcase is easily damaged. 20.
  • Page 44 b) On the centrifugal clutch side: Hit the crankcase 7.10.2 To clean and examine the crankshaft and against a piece of wood until the bearing falls crankcase out. The crankshaft cannot be repaired, replace it if it is worn or damaged. 1.
  • Page 45 7.10.3 To assemble the crankshaft and crankcase 3. Put the seal ring in the crankcase half on the flywheel side. The seal ring on the flywheel side 1. Use a snap ring pliers to attach the snap ring to the must be 5 mm below the edge of the bearing.
  • Page 46 5. Lubricate the crankshaft with some oil. Move the 7. Put the small bushing on the crankcase. Put an crankcase half on the clutch side into position. assembly sleeve on the crankshaft on the clutch side to prevent damage to the seal ring. Lubricate the crankshaft with oil and install the seal ring.

  • Page 47: Fuel Tank

    7.11 Fuel tank tank cap is damaged, the fuel tank cap must be replaced. 7.11.1 To remove and install the fuel tank and the fuel filter 7.12 Harness frame 1. Make sure that the fuel tank is empty. 7.12.1 To disassemble and assemble the harness 2.
  • Page 48 3. Remove the fuel hose from the carburetor. 5. Remove the product body from the harness frame. 4. Remove the nut and the washers. 6. Remove the 6 nuts. 7. Remove the plate. 48 - Repair instructions 935 - 001 -...

  • Page 49: Handle And Throttle Trigger

    8. Remove the vibration damping units. 12. Assemble the harness frame in the opposite sequence. 7.13 Handle and throttle trigger 7.13.1 To disassemble and assemble the handle and the throttle trigger 1. Pull up the knob and remove the drive shaft tube. 9.
  • Page 50 a) Remove the screws. Disconnect the cables and a) Remove the screw. remove the top cover. b) Pull out the throttle unit. b) Pull the throttle trigger assembly forward. Remove the throttle wire. c) Remove the throttle wire. 4. If the product has a thumb throttle handle, do these steps: 50 - Repair instructions 935 - 001 -...

  • Page 51: Gearbox

    5. Remove the start switch and the cables. b) Remove the screw and nut. Remove the bracket and remove the loop handle from the drive shaft tube. 6. Remove the rubber handle (A), if it is necessary. Loosen the screws (B and D) and pull out the drive shaft tube (C).
  • Page 52 7.14.1 To remove the gearbox 3. Remove the screws (E), the bracket (G) and the cutting attachment guard (I). Remove the bracket 1. Put a rod through the holes to lock the axle. (H) if it is not attached to the cutting attachment guard with glue.
  • Page 53 5. Remove the protective plate (N). 3. Remove the screws (B), the bracket (C) and the cutting attachment guard (E). Remove the bracket (D) if it is not attached to the cutting attachment guard with glue. 7.14.2 To remove the gearbox 1.
  • Page 54 5. Remove the protective plates (K and L). 3. Put on protective gloves. Use a hot air gun to increase the temperature of the angle gear to approximately 110°C - 140°C. Hit the gearbox against a wooden block. 7.14.3 To disassemble the bevel gear Note: The illustrations in this section shows one of the 4.
  • Page 55 6. Disassemble the bearing (X) on the output shaft 6. Install the bearings (T and U) on the input shaft (V). (AA). If it is necessary, hit the gear housing (L) Install the snap ring (S) to the input shaft (V). Make against a wooden block until the bearing falls out.
  • Page 56 8. Install the snap ring (O) for the bearing on the output shaft. Install the snap ring (P) for the bearings on the input shaft. 9. Fill the gear with grease. 10. Assemble the remaining parts in the opposite sequence to how they were disassembled. 56 - Repair instructions 935 - 001 -...

  • Page 57: Troubleshooting

    8 Troubleshooting Start The engine is not easy to start The stop screw for the throttle does not operate correctly Blocked fuel filter Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel The needle valve is defective The lever arm of the needle valve is damaged The lever arm of the needle valve does not operate correctly Blocked needle valve The needle valve is worn...
  • Page 58 Idle speed (low speed) The engine stops at idle speed The stop screw for the throttle does not operate correctly Blocked fuel filter Blocked fuel hose Air in fuel pipes The needle valve is defective Defective heat insulation seal The lever arm of the needle valve is too high The lever arm of the needle valve does not operate correctly The needle spring valve is damaged The needle valve spring is not attached correctly...
  • Page 59 Increase and decrease speed The engine stops when the speed The lever arm of the needle valve is too high is decreased The lever arm of the needle valve does not operate correctly The needle valve is worn Object in the needle valve groove The engine cannot increase Defective heat insulation seal speed...

  • Page 60: Technical Data

    9 Technical data 531RB 541RB Engine Cylinder displacement, cm 33.6 41.5 Cylinder bore, mm Stroke, mm Idle speed, rpm 2500 ± 200 2500 ± 200 Recommended max speed, rpm 12000 12000 Max. engine output, according to ISO 8893, kW @ rpm 1.1/7000-7500...
  • Page 61 935 - 001 - Technical data- 61...
  • Page 62 62 - Technical data 935 - 001 -...
  • Page 63 935 - 001 - Technical data- 63...
  • Page 64 114 10 74-26 2019-04-18...

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541rb

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