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Husqvarna 543 XP Workshop Manual

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Table of Contents
Workshop Manual
543 XP
543 XPG
English

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Table of Contents
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  Summary of Contents for Husqvarna 543 XP

  • Page 1 Workshop Manual 543 XP 543 XPG English...
  • Page 3: Table Of Contents

    Service data ............14 Safety equipment ..........16 Repair instructions ..........24 Troubleshooting........... 58 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English -...
  • Page 4: Index

    Index Index Carburettor 34 Muffler 19 Adjustment 42 Assembling the muffler 20 Assembly 38 Cleaning and inspection 19 Dismantling the muffler 19 Cleaning and inspection 38 Design 34 Dismantling 36 Function 35 Oil pump and screen 31 Pressure testing 40 Assembling the oil pump and screen 32 Cleaning and inspection 31 Centrifugal clutch 30...
  • Page 5 Index English -...
  • Page 6 Introduction and safety instructions 2 Introduction and safety regulations Contents General ...........................7 Safety ..........................7 Target group ........................7 Modifications........................7 Tools ..........................7 Structure .........................7 Numbering ........................7 General instructions ......................8 Special instructions ......................8 2.10 Symbols on the saw .......................9 2.11 Symbols in the Workshop Manual ..................9 - English...
  • Page 7: Introduction And Safety Instructions

    Some sections include an introductory Descrip- Usage is made apparent in each section. tion of the actual unit in order to increase the basic understanding. Always use Husqvarna’s original: • Spare parts 2.7 Numbering • Service tools Position references to components inside the fig- ures are designated A, B, etc.
  • Page 8 Introduction and safety instructions 2.8 General Instructions 2.9 Special Instructions The workshop where the chain saw is to be re- The fuel used in the chain saw has the following paired must be equipped with safety equipment in hazardous properties: accordance with local regulations.
  • Page 9 Introduction and safety instructions 2.10 Symbols on the chain saw 2.11 Symbols in the Workshop Manual The symbols below are embedded on the chain saw. This symbol warns of personal injury Choke Lever when the instructions are not followed. Wear protective gloves. Wear protective goggle.
  • Page 10: Technical Data

    Displacement Cylinder diameter Stroke length Max. output/speed cm3/cubic inch Ø mm/Ø inch mm/inch kW/hp/rpm 543 XP: 43,1 / 2.63 42 / 1.65 31,1 / 1.22 2,2 / 2.95 / 9 600 543 XPG: 43,1 / 2.63 42 / 1.65 31,1 / 1.22 2,2 / 2.95 / 9 600...
  • Page 11 Technical data Engage speed Spark plug Type of oil pump 543 XP: 4100 (+/- 250) NGK CMR7H Adjustable 543 XPG: 4100 (+/- 250) NGK CMR7H Adjustable Volume fuel tank Capacity oil pump at Volume oil tank Litre/US. pint 9,000 rpm, Litre/US.
  • Page 12: Service Tools

    Service tools 4 Service tools - English...
  • Page 13 Service tools Pos. Description Used for Order No. Air gap tool, ignition Setting ignition module 514 24 41-01 Piston stopper Locking the crank shaft 581 40 85-01 Wrench Clutch out or in 513 63 60-01 Puller assy Rotor out 510 13 89-01 Rod assy Piston pin out or in 521 53 35-01...
  • Page 14: Service Data

    Service data 5 Service data 8.8 - 12.7 Nm 16 mm 6.9 - 8.8 Nm 3.9 - 4.9 Nm 2.5 - 3.9 Nm 2.5 - 3.9 Nm 5.9 - 6.9 Nm 8 mm 2.0 - 3.0 Nm 5.0 - 6.5 Nm 2.9 - 3.9 Nm 0.7 - 1.5 Nm 11.8 - 14.7 Nm...
  • Page 15 Service data 1.0 - 1.5 Nm 14 mm 3.9 - 4.9 Nm 2.9 - 4.9 Nm 3.4 - 4.9 Nm 4.9 - 6.4 Nm 2.0 - 3.0 Nm 1.5 - 2.9 Nm 4.9- 6.4 Nm 2.5 - 3.9 Nm 2.5 - 3.9 Nm 2.5- 3.9 Nm 6.9- 8.8 Nm 3.4- 4.9 Nm...
  • Page 16: Safety Equipment

    Safety equipment 6 Safety equipment Contents Dismantling the chain brake ...................17 Assembling the chain brake ....................18 Dismantling the muffler ....................19 Assembling the muffler ....................20 Replacing the chain catcher ...................20 Dismantling the stop switch ....................20 Assembling the stop switch ....................20 Resistance test - stop function ..................21 Dismantling the throttle trigger lockout, throttle trigger and spring .........22 6.10 Assembling the throttle trigger lockout, throttle trigger and spring .........23...
  • Page 17: Dismantling The Chain Brake

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake WARNING! Exercise care to ensure the spring does not fly out and cause personal injury. Wear protective goggles. Fig 1 Release the brake by moving the front hand guard backward. Loosen the bar nuts and remove the clutch cover, guide bar and saw chain.
  • Page 18: Assembling The Chain Brake

    Safety equipment 6.2 Assembling the chain brake Fit the knee joint and the brake band together (see figure 5). Place the knee joint with the fitted chain brake band in the opening in the clutch cover. The space for the spring in the cover must be lubricated with grease, see figure 5.
  • Page 19: Dismantling The Muffler

    Safety equipment NOTE! After repairing, the chain brake must be in- spected in line with the instruction below. Functional inspection: Do not turn on the engine when carrying out this inspection. Guide bar length Height 13”-18” 45 cm/18" • Hold the chain saw over a stable surface. The distance between the guide bar and the sur- face is shown in the table above.
  • Page 20: Assembling The Muffler

    Safety equipment 6.4 Assembling the muffler If the muffler is fitted with a spark arrestor mesh, put it in place first. When fitting the mesh, make sure that the mesh is inserted in the right position. If necessary, use the combination spanner to insert the mesh.
  • Page 21: Resistance Test - Stop Function

    Safety equipment 6.8 Resistance test - stop switch Dismantle the stop switch as outlined in “6.6 Dis- mantling the stop switch”. Clean the contact areas. Test the resistance by connecting a multimeter to the stop switch. See figure 15. The resistance should be as follows: ”0”...
  • Page 22: Dismantling The Throttle Trigger Lockout, Throttle Trigger And Spring

    Safety equipment 6.9 Dismantling the throttle trigger lockout, throttle trigger and spring Loosen the screw on the rear handle. Remove the handle cover. See figure 16. Fig 16 Detach the spring and remove the throttle trigger lockout by pulling it upward. See figure 17. Fig 17 Remove the throttle rod from the throttle trigger, see arrow in figure 22.
  • Page 23: Assembling The Throttle Trigger Lockout, Throttle Trigger And Spring

    Safety equipment 6.10 Assembling the throttle trigger lockout, throttle trigger and spring Lubricate the pin and joined surfaces with a light oil. Slide in the throttle control and make sure the spring is fitted as outlined in figure 20. Fig 20 Fit the throttle rod on the throttle trigger.
  • Page 24: Repair Instructions

    Repair Instructions 7 Repair instructions Contents Dismantling the starter ....................25 Replacing a broken or worn starter cord ................26 Tensioning the return spring ...................26 Replacing a broken return spring ...................27 Starter assembly......................27 Removing the cylinder cover ...................27 Replacing the cylinder cover ...................27 Dismantling the ignition module and flywheel ..............28 Assembling the ignition module and flywheel ..............29 7.10...
  • Page 25: Repair Instructions

    Repair Instructions 7 Repair instructions 7.1 Dismantling the starter WARNING! If the spring tension is activated on the starter pulley, the spring can fly out and cause personal injury. Wear protective glasses. Fig 1 Loosen the three screws, which hold the starter against the crankcase and remove the starter.
  • Page 26: Replacing A Broken Or Worn Starter Cord

    Repair instructions 7.2 Replacing a broken or worn starter cord When the starter cord is worn and must be replaced, the tension in the return spring must be released. WARNING! If the spring tension is activated on the starter pulley, the spring can fly out and cause personal injury.
  • Page 27: Replacing A Broken Return Spring

    Repair Instructions 7.4 Replacing a broken return spring WARNING! Exercise care to ensure the spring does not fly out and cause person- al injury. Wear protective goggles. Loosen the screw in the centre of the pulley and remove the sprocket. See figure 4. Remove the broken spring cassette and replace it with a new one.
  • Page 28: Dismantling The Ignition Module And Flywheel

    Repair Instructions 7.8 Dismantling the ignition module and flywheel Remove the cylinder cover. Remove the starter. Snap off the ignition cable from the air guide plate and remove the air guide plate. See figure 9. Fig 9 Knock out a few of the pins in the tool if it does not match up with the flywheel.
  • Page 29: Assembling The Ignition Module And Flywheel

    Repair Instructions 7.9 Assembling the ignition module and flywheel Place the ignition module in position and fit the Three bond #1342 screws. See figure 13. Do not tighten the screws. Fig 13 Fit the flywheel onto the crankshaft pin. Turn the flywheel until the key fits into the key slot on the shaft.
  • Page 30: Dismantling The Centrifugal Clutch

    Repair Instructions 7.10 Dismantling the centrifugal clutch Remove the cylinder cover. Release the brake by moving the front hand guard backwards. Loosen the bar nuts and remove the clutch cover, saw chain and guide bar. See figure 16. Fig 16 Remove the spark plug hat and the spark plug.
  • Page 31: Assembling The Centrifugal Clutch

    Repair Instructions 7.11 Assembling the centrifugal clutch Use special tool 513 63 65-01 and assemble the clutch according to figure 20. Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 513 63 60-01 and a suitable socket wrench or combination span- ner.
  • Page 32: Dismantling The Intake System

    Repair Instructions 7.13 Assembling the oil pump and screen Lower the oil filter in place and replace the oil pump as outlined in figure 22 and tighten the screws. Fit the pump drive wheel and apply three bond #1322 (thread lock) to the screws. Fit the chain guide plate.Tightening torque 1,5-2,9 Nm.
  • Page 33: Assembling The Intake System

    Repair Instructions 7.15 Assembling the intake system Fit the inlet pipe assy, B. See figure 25. Fit the intake flange, C. See figure 25. Three bond #1322 Fit the carburettor and the throttle rod as outlined in “Assembling the carburettor”. Fit the air filter, the filter holder, the cable from the intake flange holder.
  • Page 34: Carburettor

    Repair Instructions 7.16 Carburettor WARNING! The fuel used in the chain saw has the following hazardous properties: 1. The fluid and its vapour are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Description The images for this description do not correspond to the carburettor on the chain saw.
  • Page 35 Repair Instructions Function The carburettor functions differently in the following modes: Cold start mode In cold start mode the choke valve D is completely shut. This increases the vacuum in the carburettor and fuel is easier to suck from all the diffuser jets E, F and G.
  • Page 36 Repair Instructions Dismantling the carburettor Remove the cylinder cover and the air filter. Remove the manifold. See figure 33. Fig 33 Detach hose A, B and C from the carburettor. See figure 34. Unhook the choke and throttle rods. See figure 34B. Remove the carburettor.
  • Page 37 Repair Instructions Remove screw P and needle valve M with lever arm Q, shaft L and spring R. See figure 36. Fig 36 Remove screw Z and remove gasket Y and dia- phragm X. See figure 37. Use a needle or similar device and carefully pull up the fuel screen (W).
  • Page 38 Repair Instructions If necessary, dismantle throttle valve T and the High (S) and Low (P) jet screws valve. Remove the shafts with lever arms and springs. See figure 38. Cleaning and inspection Clean all units in clean petrol. Use compressed air to dry the petrol on the com- ponents.
  • Page 39 Repair Instructions 4. Assemble needle valve M with lever arm Q, shaft L and spring R, and tighten screw P. See figure 40. Fig 40 5. Check using a ruler or the like that the lever is level with the assembly plane on the cover. If necessary, the lever arm can be bent, see figure 41.
  • Page 40 Repair Instructions Pressure testing the carburettor Pressure testing should be carried out with the car- burettor fully assembled. Testing should always be carried out after the carburettor has been repaired, but a test can also be made for troubleshooting before dismantling. Option 1 Carry out the check as follows: Connect pressure tester to the carburettor fuel inlet.
  • Page 41 Repair Instructions Fitting the carburettor Fit the carburettor. Fit the pulse hose A, the input hose B, and the tank return hose C. See figure 44. Fit the manifold. See figure 45. Fit the choke and throttle rods to the carburettor. See figure 45B.
  • Page 42 Repair Instructions Adjustment WARNING! The guide bar, saw chain and clutch cover must be fitted before the chain saw is started, other- wise the clutch may come loose causing personal injury. WARNING! Wear ear defenders when making adjustments with the engine run- ning.
  • Page 43 Repair Instructions Basic adjustment for chain saws with ignition system (IKEDA UK-09701) and carburettors without limiters (Walbro HD-54B) To ensure that the engine components receive adequate lubrication (running in) the carburettor should be set to a somewhat richer fuel mixture for the chain saw's first 3-4 running hours. This is done by adjusting the maximum speed to 600-700 rpm less than the recommended maximum speed.
  • Page 44: Tank Unit

    Repair Instructions 7.17 Tank unit WARNING! The fuel used in the chain saw has the following hazardous properties: 1. The fluid and its vapour are poisonous. 2. Can cause skin irritation. 3. Is highly inflammable. Dismantling 1. Drain the fuel from the tank. 2.
  • Page 45: Vibration Damping System

    Repair Instructions 7.18 Vibration damping system Dismantling Remove the plastic lids and rubber dampers on both sides. See figures 48-49. Cleaning and inspection • Clean and inspect all parts carefully. If there are any cracks or other defects, replace the damaged parts with new ones.
  • Page 46: Replacing The Fuel Filter

    Repair Instructions 7.19 Replacing the fuel filter NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. When replacing the fuel filter, the old fuel filter must be taken out of the tank unit using special tool 502 50 83-01.
  • Page 47: Handle Heating System

    Repair Instructions 7.22 Handle heating system (543 XPG) The handle heating system comprises the following: • Generator • Power switch • Heating elements in the rear handle and the front handle bar. Troubleshooting Troubleshooting requires: • Ammeter • Ohmmeter • Coolant Oxidation of the connectors in the heating elements in the rear handle and the power switch’s...
  • Page 48 Repair Instructions Troubleshooting the heating element, rear handle Connect the multimeter as outlined in Figure 55 and measure the resistance in the rear handle’s heating element. The multimeter reading should indicate between 0.4 Ω and 0.6 Ω. Replace the heating element if you get another reading.
  • Page 49: Dismantling The Piston And Cylinder

    Repair Instructions When replacing the generator, use special tool 512 41 31-01 to fix the heating coil. Also, apply three Three bond bond #1322 (thread lock) or similar to the screws. #1322 See figure 57B. Tightening torque 2,9 - 3,9 Nm. Fig 57B 7.23 Dismantling the piston and cylinder Dismantle the:...
  • Page 50 Repair Instructions Cleaning and inspection of the cylinder Clean all components, scrape off all gasket re- mains and soot from the following areas: • Piston crown • Top of the cylinder bore (inside) • Cylinder exhaust port • Base of the cylinder and/or crankcase Check the following: •...
  • Page 51: Assembling The Piston And Cylinder

    Repair Instructions 7.24 Assembling the piston and cylinder Oil the gudgeon pin bearing with two-stroke oil and insert the crank rod. Se figure 63. Attach the piston with the arrow facing the exhaust port. Slide in the gudgeon pin and fit the circlips. Note! Use new circlips.
  • Page 52: Leakage/Compression Testing The Cylinder

    Repair Instructions 7.25 Leakage testing Remove the: • cylinder cover • carburettor • spark plug Attach the cover plate 574 71 14-01 and plug 503 84 40-03. See figure 65. Loosen the screws on the muffler and press the Fig 65 cover plate 502 54 11-02 between the muffler and cylinder (remove the muffler gasket).
  • Page 53: Dismantling The Crankshaft And Crankcase

    Repair Instructions Cylinder compression test Remove the spark plug and fit the pressure test tool art.nr 531 03 16-86. Use the 10mm adapter 583 84 98-01. Pull the starter handle to measure the compres- sion in the cylinder. The compression should not be under 686 kPa (7Kg/cm2).
  • Page 54 Repair Instructions Cleaning and inspection NOTE! If the bearings are fitted to the crankcase, take care to prevent any dirt and foreign particles from entering. Clean all parts and scrape off all gasket remains from the contact surfaces on the crankcase halves. Check the following: 1.
  • Page 55 Repair Instructions Assembly: bearings & oil seals NOTE! Take care to prevent any dirt and foreign particles from entering the bearings. Proceed as follows if new bearings and oil seals must be fitted: Fit the bearing in the flywheel side of the crank- case half.
  • Page 56 Repair Instructions Fit the crankshaft to the PTO side of the crank- case. Note! Fit the guide, 513 70 59-01, to the crankshaft journal before the crankshaft is inserted. The guide prevents the oil seal from getting dam- aged. Remove the guide afterwards. See figure 74 Place the guide pegs in the PTO side half.
  • Page 57 Repair Instructions Fit the piston assembly tool (against rotation). Use the crankshaft assembly tool 502 50 30-22 and pull the crankshaft into the MAG side of the crankcase. Se figure 76. Fix the six crankcase bolts. Tighten them alternate- ly. Tightening torque 6,9 - 8,8 Nm. See figure 77. Refit remaining parts.
  • Page 58: Troubleshooting

    Troubleshooting 8 Troubleshooting Contents Troubleshooting ......................59 Troubleshooting methods ....................60 - English...
  • Page 59 Troubleshooting 8.1 Troubleshooting The various faults that can affect a chain saw are divided into four groups. In each group the likely symptoms are given on the left and possible causes are listed on the right. The most likely faults are given first, and so on.
  • Page 60 Troubleshooting High rpm Acceleration och retardation Will not run at Adjust H screw Does not Adjust L screw accelerate Adjust H screw full throttle Blocked air filter Blocked air filter Blocked fuel tank vent Blocked fuel tank vent Blocked fuel filter Blocked fuel filter Fuel line blocked Fuel line blocked...
  • Page 62 • 115 50 87-26 2014W39...

This manual is also suitable for:

543 xpg120125