Husqvarna 565 Workshop Manual
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Husqvarna 565 Workshop Manual

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Workshop manual
565, 572XP, 572XPG
English
English - 1

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Summary of Contents for Husqvarna 565

  • Page 1 Workshop manual 565, 572XP, 572XPG English English - 1...

  • Page 2: Table Of Contents

    Workshop Manual 565, 572XP, 572XPG Contents 1 Introduction and safety regulations ......3 13.2 Cleaning and inspection ..............30 13.3 Assembly ....................31 1.1 General ......................3 13.3.1 Adjustment of the pump feed rate..........31 1.2 Safety ......................3 14 Carburettor ..............32 1.3 Target Group ....................3 14.1 Description ..................32...

  • Page 3: Introduction And Safety Regulations

    Introduction and safety regulations 1 Introduction and safety regulations 1.5 Layout 1.1 General This Workshop Manual can be used in two different This Workshop Manual provides a comprehensive ways: description of how to trouble shoot, repair and test the chainsaw. A description of different safety measures •...

  • Page 4: General Instructions

    Introduction and safety regulations 1.1 General instructions 1.2 Special instructions The workshop where chainsaw repairs are to be done The fuel used in the chainsaw has the following must be equipped with safety equipment as set out in hazardous properties: local regulations.

  • Page 5: Symbols On The Chainsaw

    Introduction and safety regulations 1.3 Symbols on the chainsaw 1.4 Symbols in this Workshop Manual The following symbols are moulded into the chainsaw casing. This symbol indicates a risk of personal Choke injury if instructions are not followed. Use protective gloves. Switch for hand grip heater Use protective goggles.

  • Page 6: Technical Data

    Technical data 2 Technical data Displacement Bore Stroke Max. power/rpm / cubic inch Ømm/Øinch mm/inch kW/hp / rpm 70,6/4,3 48/1,9 39/1,5 3,7/5,0/ 9 300 572 XP 70,6/4,3 48/1,9 39/1,5 4,3/5,8 / 9 900 572 XPG 70,6/4,3 48/1,9 39/1,5 4,3/5,8 / 9 900 Spark plug gap Ignition system Air gap...
  • Page 7 Technical data Idling speed Engage speed Max. speed Spark plug 2 700 3 600 13 000 NGK BPMR7A 572 XP 2 700 3 600 13 300 NGK BPMR7A 572 XPG 2 700 3 600 13 300 NGK BPMR7A Fuel tank volume Oil pump capacity Oil tank volume Automatic oil pump...

  • Page 8: Service Tools

    Service tools 3 Service tools 8 - English...
  • Page 9 Service tools The tools listed here are service tools intended for use on the chainsaw in question. In addition to these tools, a standard set of hand tools is required. Item Description Used for Article number Piston stop Locking the crankshaft 502 54 15-01 Cover plate, exhaust Sealing the exhaust port...

  • Page 10: Service Data

    Service data 4 Service data 572XP/G, 565 8.5Nm 1.5Nm 20Nm 19mm 17Nm 17Nm 13Nm 13mm 1.5Nm 1.5Nm 3.5Nm 5-6Nm 15Nm 13mm 1-2Nm 4.5Nm 20Nm Key to diagrams = Lubricate with two-stroke oil. The figures next to parts screwed on indicate = Lubricate with chain oil.
  • Page 11 Service data 572XP/G, 565 (XPG) 14Nm (XPG) 23Nm 13mm 2.5Nm English - 11...

  • Page 12: Chain Brake

    Chain brake 5 Chain brake 5.1 Dismantling 1. Dismantle the following parts first: • Chain and bar. • Clutch cover. 2. Remove the chain guide-plate (A). See figure 1. Fig. 1 3. Remove the locking ring (A) with washer (B) and lift up the clutch drum (E) with needle bearing (D) and chaindrive sprocket (C).

  • Page 13: Cleaning And Inspection

    Chain brake 5.2 Cleaning and inspection Clean and inspect all parts. The thickness of the brake band must nowhere be less than 0,8 mm. See figure 5. Min. 0.8 mm Fig. 5 5.2.1 Cleaning and inspection of the air channel This chainsaw is equipped with an air channel that reached from the flywheel side to the clutch side.

  • Page 14: Assembly

    Chain brake 5.3 Assembly 1. Fit the hand guard with the sleeves on the chainsaw. Attach the hand guard on the starter side (B). See figure 8. Make sure that the sockets on the hand guard are intact. 2. Grease the moving parts of the toggle joint (D) and Fig.

  • Page 15: Function Check

    Chain brake 5.4 Function check WARNING! After repair, you have to carry out a function check of the chain brake. For this test, the engine must not be running. Check that the chain brake engages as follows: 1. Hold the chainsaw over a stable surface as shown in figure 10.

  • Page 16: Chain Catcher

    Chain catcher 6 Chain catcher There are two types of mountings for the chain catcher fitted on the spike bumper or the crankcase. Dismantle the bar and chain. Inspect the chain catcher and replace it if it is damaged (one screw). See figure 1. Fit the bar and chain.

  • Page 17: Muffler

    Muffler 7 Muffler 7.1 Dismantling 1. Remove the cylinder cover. WARNING! Do not touch the muffler until it has cooled. Risk of burn injuries. 2. Remove the spark-arrester if one is fitted (one screw). See figure 1. 3. Remove the four bolts. See figure 1. 4.

  • Page 18: Start/Stop Switch

    Start/stop switch 8 Start/stop switch 8.1 Dismantling Remove the cylinder cover and air filter. Unscrew the two screws from the air filter holder (A). See figure 1. Unhook the air purge from the air filter holder (B). See figure 1. Dismantle the cables connected to the contact clamp (C).

  • Page 19: Throttle Trigger Lockout, Throttle Trigger And Spring

    Throttle trigger lockout, throttle trigger and spring 9 Throttle trigger lockout, throttle trigger and spring 9.1 Dismantling Remove the bar, chain and cylinder cover. Loosen the screw to the vibration damping unit on the starter side. See figure 1. Fig. 1 Unscrew the screw on the rear handle (A) and remove the handle insert (B).

  • Page 20: Replace A Defect Throttle Cable

    Throttle trigger lockout, throttle trigger and spring 9.3 Replace a defect throttle cable Unscrew the screw attached to the vibration damping unit on the clutch side (A). See figure 6. Unscrew the screw inside the handle that is attached to the cylinder (B). See figure 6. Unscrew the remaining screws (C and D) on the Fig.

  • Page 21: Starter

    The dogs on the starter pulley. • That the pawls on the flywheel are intact and that the spring is back towards the centre and moves freely. 3. Grease the spring in the starter pulley with Fig. 3 Husqvarna UL 22. English - 21...

  • Page 22: Assembly

    Starter 10.3 Assembly WARNING! If the spring is tensioned on the starter pulley it can fly up and cause personal injury. 1. If a new spring is to fitted, replace the whole casette. Make sure that the spring i placed against the Fig.

  • Page 23: Ignition System

    Ignition system 11 Ignition system 11.1 Dismantling 1. Remove the cylinder cover and starter unit. See chapter Starter. 2. Disconnect the cables to the ignition module that is connected to the contact on the Autotune unit. See chapter Start/stop switch. 3.

  • Page 24: Assembly

    Ignition system 11.3 Assembly 7. Insert the feeler gauge Air Gap Tool (0.3 mm) between the ignition module and the flywheel 1. Fit the flywheel on the shaft. Turn it gently until the magnet. The clearance only applies to the two lower key on the flywheel mates with the recess in the pegs on the ignition module.

  • Page 25: Autotune

    Ignition system 11.4 AutoTune The cables connected to the start/stop switch are attached onto the carburettor (A). The cables connected to the ignition module are attached to the autotune unit (B). The white contact must be fastened on the autotune unit. Fig.

  • Page 26: Replacing The Generator (Xpg)

    Ignition system 11.5 Replacing the generator (XPG) 1. The following components must be removed before the generator can be replaced: A. Starter. See figure 10. B. Flywheel. See figure 10. C. The rear vibration damping unit. See figure 10. 2. Unscrew the cover on the front handle. See figure Fig.

  • Page 27: Replacing The Switch (Xpg)

    Ignition system 11.6 Replacing the switch (XPG) To replace the switch the following must be dismantled (see chapter Replacing the generator): • Front handle (five to six screws). • Cables in the front handle (three). 2. Unscrew the screw holding the switch (A). 3.

  • Page 28: Centrifugal Clutch

    Centrifugal clutch 12 Centrifugal clutch 12.1 Dismantling Make sure that the chain brake is disengaged. 2. Remove the cylinder cover, bar and chain. 3. Unscrew the bolt and remove the chain guide plate (A). See figure 1. 4. Remove the locking ring (B) with washer and lift up the clutch drum (C) with needle bearing (D) and chain drive sprocket (E).

  • Page 29: Cleaning And Inspection

    Centrifugal clutch 12.2 Cleaning and inspection Clean all components and check the following: 1. That there is no play between the clutch shoes and the clutch hub. 2. That there is no wear on the chain drive sprocket. 3. That the needle bearing is in good condition and that there is no damage on the journal surface on the crankshaft.

  • Page 30: Lubrication System

    Lubrication system 13 Lubrication system WARNING! Insufficient lubrication of the chain can result in the chain breaking, which can cause serious or even life- threatening injury. The lubrication system consists of the following parts: • Oil pump. • Suction hose with filter. •...

  • Page 31: Assembly

    Fig. 8 for different lengths of guide bar. The table applies to Husqvarna chain oil. If another chain oil is used, the adjuster should be turned one extra turn outward in the first three cases.

  • Page 32: Carburettor

    Carburettor 14 Carburettor WARNING! The fuel used in the chainsaw has the following hazardous properties: 1. The fluid and its vapour are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 14.1 Description The figures accompanying this description do not correspond with the carburettor on the chainsaw.

  • Page 33: Function

    Carburettor 14.3 Function The carburettor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In cold start mode the choke valve (H) is completely shut. This increases the vacuum in the carburettor and Fig 4 fuel is easier to suck from all the diffuser jets (D), (E), and (F).

  • Page 34: Dismantling The Carburettor

    Carburettor 14.4 Dismantling the carburettor Remove the cylinder cover and the air filter. Disconnect the contact to the Autotune unit and the stop wiring contact (G). See figure 8a. XPG: Unscrew the contact clamp (two screws) (H) and remove the thermostat (I). See figure 8b. Remove the screws (E).
  • Page 35 Carburettor 10. Snap off the connector from the Autotune unit using a small flat screwdriver. Separate the connector by pressing down the catch with screwdriver and pulling the unit apart. See figure 11. NOTE! Do not dismantle the AutoTune unit from the carburettor body.

  • Page 36: Cleaning And Inspection

    Carburettor 14.5 Cleaning and inspection CAUTION! Observe cleanliness when assembling the carburettor. The slightest Clean all units in clean petrol. contamination can result in downtime. Use compressed air to dry the petrol. Direct the air If the throttle and choke valves with shafts, lever through all channels in the carburettor housing and arms and springs are removed, these must be as- ensure that they are not blocked.

  • Page 37: Adjustment Of Autotune At Change Of Carburettor

    Carburettor 5. Assemble needle valve (K) with lever arm (M), shaft (J) and spring (N), and tighten screw (L)(Fit the expansion washer). See figure 14. Fig 14 6. Check that the lever arm (M) is 0.05-0.25 mm under the plane of the gasket surface using a ruler or the like.

  • Page 38: Fitting The Carburettor On The Chainsaw

    Carburettor 14.8 Fitting the carburettor on the chainsaw NOTE! When replacing the carburettor, a firmware download is required on the new unit and it has to pass the test “autotest” in CST before use. See instruction in CST. (Documents/Handheld/Auto- Tune/User Guide). Press the connector together and push it into place in the holder.
  • Page 39 Carburettor Position the guide taps on the air filter holder in the rubber mountings (G). See figure 21. CAUTION! Make sure that the spring is fitted under the choke pin on the carburettor. See figure 20. Attach the throttle cable (D). See figure 22. Fasten the return hose (B) and secure it in its mountings on the air filter holder.

  • Page 40: Manifold

    Carburettor 14.9 Manifold The intake system has two inlets. 1. The upper intake (E) lets fuel and air mixture from the carburettor into the cylinder (G). See figure 23. 2. The lower intake (F) lets air into the cylinder (G). See figure 23.

  • Page 41: Tank Unit

    Tank unit 15 Tank unit WARNING! The fuel used in the chainsaw has the following hazardous properties: The fluid and its fumes are poisonous. Can cause skin irritation. Is highly inflammable. 15.1 Dismantling 1. Drain the fuel from the tank. 2.

  • Page 42: Tank Valve

    Tank unit 15.5 Tank valve The tank valve is a two-way valve and has the following features: • Controlled opening pressure in both directions, which prevents excess of pressure or vacuum developing in the fuel tank and impairing engine operation. •...

  • Page 43: Anti-Vibration System

    Anti-vibration system 16 Anti-vibration system WARNING! The fuel used in the chainsaw has the following hazardous properties: 1. The fluid and its fumes are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. 16.1 Dismantling 1. Dismantle the following parts: •...

  • Page 44: Piston And Cylinder

    Piston and cylinder 17 Piston and cylinder 17.1 Dismantling 1. Dismantle the following parts: • Cylinder cover. • Spark plug. • Carburettor. See chapter Carburettor. • Muffler. See chapter Muffler. 2. Unscrew the vibration damping unit (C) from the Fig. 1 cylinder.
  • Page 45 Piston and cylinder Check the following: 1. That the cylinder’s surface coating is not worn. Especially in the upper end of the cylinder. 2. That the cylinder is free of score marks. See figure 4. 3. That the piston is free of score marks. Minor scratches can be polished off with fine emery paper.

  • Page 46: Assembly

    Piston and cylinder 17.3 Assembly CAUTION! Exercise care so that dirt and foreign particles do not get into the crankcase. 1. Lubricate the needle bearing (A) and fit it in the connecting rod. See figure 7. 2. Place the piston with the arrow facing the exhaust port.

  • Page 47: Crankcase And Crankshaft

    Crankcase and crankshaft 18 Crankcase and crankshaft 18.1 Dismantling Before the crankcase can be separated the following parts must be dismantled: A. Bar and chain. B. Starter. See chapter Starter. C. Ignition system. See chapter Ignition system. D. Centrifugal clutch. See chapter Centrifugal clutch. E.

  • Page 48: Cleaning And Inspection

    Crankcase and crankshaft 7. If the crankshaft bearing remains on the crankshaft, remove it with the Puller tool. See figure 6. Fig. 6 18.2 Cleaning and inspection CAUTION! If the bearings are mounted in the crankcase, exercise care to avoid dirt and foreign particles getting in.

  • Page 49: Assembly

    Crankcase and crankshaft 18.3 Assembly 1. Clutch side: Place Guide shaft (clutch side, bottom) in a vice and place the bearing on top of the Guide shaft (clutch side, bottom) with sealing upwards. Use Sleeve (clutch and flywheel side, top), screw and nut to fit the bearing on the clutch side of the crankcase.
  • Page 50 Crankcase and crankshaft 3. Use the Crankshaft assembly tool. Use back side of sleeve (B) and pull the crankshaft into the clutch side’s crankcase half. Pull until the crankcase shoulder mates with the bearing. See figure 10. For instructions, see https://youtu.be/MhCGXdarusM 4.

  • Page 51: Seals

    Crankcase and crankshaft 18.4 Seals 1. To replace the seals on the crankshaft, remove the following parts: On the flywheel side: • Starter. • Flywheel. • XPG: Generator. On the clutch side: • Chain and bar. • Chain guide plate. Fig.

  • Page 52: Troubleshooting

    Troubleshooting 19 Troubleshooting 19.1 Troubleshooting for hand grips and carburettor heater (XPG) Some chainsaws are fitted with hand grip heaters and carburettor heaters, and consist of the following parts: • Generator. • Switch. • Heating element in rear hand grip. •...

  • Page 53: Troubleshooting Of The Piston

    Troubleshooting 19.2 Troubleshooting of the piston Score marks in Incorrect carburettor setting. Too high maxspeed. the piston (A). Too low octane fuel. Too little or incorrect oil in the fuel. Carbon build-up (B). Incorrect carburettor setting. Too low maxspeed. Too much or incorrect oil in the Fig.

  • Page 54: Pressure Testing The Crankcase And Cylinder

    Troubleshooting 19.4 Pressure testing the crankcase and cylinder The following parts must be removed before carrying out a pressure test of the crankcase and cylinder: • Air filter. • Carburettor. Carry out a pressure test as follows: 1. Fit the cover plates on the intake manifold.
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