Husqvarna 543RBX Workshop Manual
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Workshop manual
543RBX, 543RBK, 553RBX
English
1239 - 001 -

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Table of Contents
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Summary of Contents for Husqvarna 543RBX

  • Page 1 Workshop manual 543RBX, 543RBK, 553RBX English 1239 - 001 -...
  • Page 2: Table Of Contents

    2.4 Symbols on the product......... 4 3 Prepare and do servicing on the product 3.1 Maintenance schedule........... 5 4 Servicing data 4.1 Servicing data (543RBX, 543RBK)......6 4.2 Servicing data (553RBX)........10 5 Servicing tools 6 Function overview 6.1 Type plate/Product serial number......16 6.2 Fuel..............
  • 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. 1239 - 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 (543RBX, 543RBK) 3 - 6 Nm 2.5 - 4 Nm 3 - 6 Nm 9 - 13 Nm 3 - 6 Nm 5 - 7 Nm 6 - 9 Nm 2.9 - 3.9 Nm ▲...
  • Page 7 2 - 3 Nm 3 - 5 Nm 3 - 5 Nm 2 - 4 Nm 15 - 20Nm 17 mm 3 - 5 Nm 1239 - 001 - Servicing data - 7...
  • Page 8 3 - 5 Nm 1.5 - 2 Nm 8 - 10 Nm 6 - 8 Nm 5 - 10 Nm 13 mm 5 - 10 Nm 13 mm 6 - 8 Nm 6 - 8 Nm 8 - Servicing data 1239 - 001 -...
  • Page 9 1.6 - 2.5 Nm 1.6 - 2.5 Nm 2 - 3 Nm 2.5 - 3.5 Nm 2 - 3 Nm 1239 - 001 - Servicing data - 9...
  • Page 10: Servicing Data (553Rbx)

    4.2 Servicing data (553RBX) 3 - 6 Nm 2.5 - 4 Nm 3 - 6 Nm 2.5 - 3.5 Nm 3 - 6 Nm 3 - 6 Nm 6 - 9 Nm 0.4 - 0.8 Nm 7.8 - 8.3 Nm ▲...
  • Page 11 2 - 3 Nm 3 - 5 Nm 3 - 5 Nm 15 - 20Nm 17 mm 3 - 5 Nm 1239 - 001 - Servicing data - 11...
  • Page 12 3 - 5 Nm 1.5 - 2 Nm 5 - 10 Nm 13 mm 6 - 8 Nm 12 - Servicing data 1239 - 001 -...
  • Page 13 1.6 - 2.5 Nm 1.6 - 2.5 Nm 2 - 3 Nm 2.5 - 3.5 Nm 2 - 3 Nm 1239 - 001 - Servicing data - 13...
  • Page 14: Servicing Tools

    5 Servicing tools 14 - Servicing tools 1239 - 001 -...
  • Page 15 Torx T27 Remove and attach torx screws. 502 71 27-03 Piston assembly kit Assemble the piston. 502 50 70-01 Removal tool for 543RBX, 543RBK Remove the starter pawl assembly. 581 96 55-01 Snap ring pliers Remove snap rings. Pliers N/A.
  • Page 16: 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 17: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions (543RBX, 543RBK) 1. Starter 7. Flywheel 2. Muffler 8. Cylinder and piston 3. Air filter 9. Crankcase and crankshaft 4. Carburetor 10. Fuel tank 5. Clutch and clutch drum 11. Frame and harness 6.
  • Page 18: Product Overview For Repair Instructions (553Rbx)

    13. Gearbox (543RBX) 14. Gearbox (543RBK) 7.2 Product overview for repair instructions (553RBX) 1. Starter 9. Crankcase and crankshaft 2. Muffler 10. Fuel tank 3. Air filter 11. Frame and harness 4. Carburetor 12. Handle and throttle trigger 5. Clutch and clutch drum 13.
  • Page 19: To Clean And Examine The Product Parts

    7.3 To clean and examine the product parts 3. Let the starter pulley rotate rearward until the spring tension loosens. • Clean and examine all parts fully. You find more instructions in the chapter for each part if special tools or procedures are necessary. •...
  • Page 20 6. Remove the starter pulley. The recoil spring is in the 4. Attach a new starter rope to the starter pulley. Make starter housing. a small knot and make sure that it can be put into the notch in the pulley. WARNING: Be very careful when you remove the starter pulley.
  • Page 21 8. Tighten the recoil spring. 3. Use the removal tool to remove the starter pawl Servicing tools on page 14 . assembly. Refer to 9. Attach the starter unit to the crankcase. 4. Examine the starter pawl assembly. a) Clean the starter pawl assembly if it is dirty. b) Remove the snap ring that holds the starter pawl.
  • Page 22: Muffler

    7.5 Muffler 5. Remove the screws and the holder, if it is necessary. 7.5.1 To remove and install the muffler 1. Remove the 4 screws and the cylinder cover. 6. Install the muffler in the opposite sequence. 7.5.2 To clean and examine the muffler WARNING: Risk of burn injury or fire.
  • Page 23: Air Filter

    7.6 Air filter damaged air filter. Clean the air filter at an interval of 25 hours of operation. 7.6.1 To remove and install the air filter 1. Turn the engine around its axle to get access to the If you use an air filter for a long time, it cannot be fully air filter.
  • Page 24 and throttle valve (A) are found here. The main jet is in diaphragm is operated by pressure variations in the the middle of the venturi. engines crankcase through an impulse channel (B). If the impulse channel is blocked, by grease or an incorrectly installed gasket, the pump unit does not operate.
  • Page 25 7.7.2 Carburetor (543RBX, 543RBK) 7.7.2.1 Overview of the carburetor (543RBX, 543RBK) 1239 - 001 - Repair instructions- 25...
  • Page 26 7.7.2.2 To disassemble the carburetor Gasket 1. Turn the engine around its axle to get access to the Diaphragm air filter and carburetor. Cover Gasket Diaphragm Fuel screen Main jet Plug 2. Remove the air filter cover and the air filter. 26 - Repair instructions 1239 - 001 -...
  • Page 27 3. Remove the fuel hoses (A and B) from the primer 8. Remove the 3 screws and the distance piece, the pump. gaskets and the throttle wire, if it is necessary. 9. Remove the 4 screws and the cover. Remove the metering diaphragm (F) and the gasket (E).
  • Page 28 10. Connect the pressure tester to the fuel hose. Lower b) Examine the lever arm and the needle valve for the carburetor in a vessel with gasoline to find leaks. wear and damage. Do a test of the pressure at 50 kPa. c) Remove the screw and remove the cover (G).
  • Page 29 Remove the jet needles. 7.7.2.3 To assemble the carburetor 1. Blow compressed air through the channels of the carburetor. 2. Install a new main jet (K). 3. Attach the valves and springs. g) Remove the main jet (K). 4. Replace the fuel screen if it is damaged or cannot be cleaned.
  • Page 30 7. Attach the pressure tester to the fuel inlet on the 9. Make sure that the air hole is open and attach the carburetor. Pump up the pressure to 50 kPa. Lower cover. the carburetor in a container with gasoline to find leaks.
  • Page 31 7.7.3 Carburetor (553RBX) 7.7.3.1 Overview of the carburetor (553RBX) 1239 - 001 - Repair instructions- 31...
  • Page 32 3. Remove the fuel hose (A). Diaphragm Connecting Gasket Cover Diaphragm Gasket Screw Diaphragm Axle Fuel screen Lever arm Low speed needle Cover High speed needle Needle Hub cap valve Screw Plug Body Main jet Sealing Grease nip- rings Impulse 4.
  • Page 33 6. Remove the 2 screws (F) and the plate (G). 11. Remove the 4 screws and the cover. Remove the control diaphragm (P), gasket (Q) and cover (V). Examine the diaphragm for damage and wear on the pin (R). 7. Remove the air filter holder (H), bracket holder (I) and carburetor (J).
  • Page 34 14. Loosen the bolt and remove the lever arm, axle, 17. Remove the bolt and the cover (AB). needle valve and spring. 15. Examine the wear to the lever arm and the needle valve for damage. 18. Remove the gasket (AC) and the diaphragm (AD). Examine the diaphragm for damage.
  • Page 35 21. Remove the main jet (AJ) and remove the plug (AI). 7. Attach and adjust the jet needles. 7.7.3.3 To assemble the carburetor Note: The end of the high speed needle (AG) is 1. Blow compressed air through the channels of the slightly thinner than that of the low speed needle carburetor.
  • Page 36 11. Attach the gasket (Q). 15. Attach the pump diaphragm (AD), the gasket (AC) and the cover (AB). 12. Attach the control diaphragm (P). Make sure that the handle points in the direction of the lever arm. 13. Attach the cover (V). Make sure that the hose connector (AK) is aligned to the choke valve.
  • Page 37 Turn the idle adjustment screw clockwise to get a higher idle speed and turn it counterclockwise to get a lower idle speed. Note: The illustration refers to 543RBX, 543RBK, but Carburetor adjustments at the factory the procedure applies also to 553RBX.
  • Page 38: Clutch And Clutch Drum

    9000 rpm. If the speed is lower than this, adjust with a high speed needle. To adjust the carburetor (553RBX) Use Husqvarna T45 trimmer head with silent cord ø 3.0 mm. The length of the trimmer line will adjust by the knife on the original cutting attachment guard.
  • Page 39 4. Remove the 4 screws and the clutch drum housing. 7. Use pliers to remove the snap ring (F) and the bearing (G). 7.8.2 To clean and examine the centrifugal clutch 1. Examine the spring and outer edge for wear and damage.
  • Page 40: Ignition System

    7.8.3 To install the centrifugal clutch 7.9.3 To do a spark test of the ignition module 1. Put some grease on the clutch screw, but not on the 1. Disconnect the spark plug cable from the spark plug. thread. 2. Disconnect the spark plug from the cylinder. 3.
  • Page 41 7.9.4 To examine the spark plug cable 5. Put the spring into the new hole. If there is no spark when you do a spark test of the ignition module, you must examine the spark plug cable. 1. Remove the ignition module. Refer to disassemble the ignition system on page 42 .
  • Page 42 8. Use the assembly pliers or a screwdriver to align the 7.9.5 To disassemble the ignition system spring with the hole in the spark plug cap. 1. Pull up the knob and remove the drive shaft tube. 2. Remove the throttle wire (A) from the throttle wire WARNING: Be very careful to prevent joint (B).
  • Page 43 3. Remove the 4 screws and the cylinder cover. 5. Remove the screws, the flywheel cover and clutch drum assembly. 4. Remove the spark plug cap from the spark plug. Remove the spark plug and put a piston stop in the 6.
  • Page 44 7. Remove the screw, the cable (D) and the cable (E) 10. Remove the nut and remove the flywheel. Remove from the ignition module. the key from the crankshaft. 8. If it is necessary, pull up the cables (D and E) from 7.9.6 To examine the ignition system behind the crankcase.
  • Page 45 7.9.7 To assemble the ignition system 3. Connect the cables (C) and (D) to the ignition module. 1. Attach the flywheel. Make sure that the key is in the correct position when you install the flywheel. 4. Use a feeler gauge to make sure that the distance between the ignition module and the flywheel is 0.3 2.
  • Page 46: Cylinder And Piston

    7.10 Cylinder and piston 13. Put a cloth above the crankcase to make sure that no dirt goes into the crankcase. 7.10.1 To disassemble the cylinder and piston 1. Pull up the knob and remove the drive shaft tube. 2. Remove the cylinder cover. 3.
  • Page 47 15. Push the piston pin from the piston with a piston pin 7.10.2 To clean the cylinder and piston rod. CAUTION: Be careful when you clean the piston and cylinder. The soft aluminum parts are easily damaged. • Remove the carbon deposits from these parts: 16.
  • Page 48 • Make sure that the cylinder does not have score • Measure the piston ring play (B). Replace the piston marks. ring if the piston ring play is larger than 0.1 mm. • Put the piston ring in the cylinder and measure the space with an air gap tool.
  • Page 49 4. Push the piston pin into the piston and attach the 9. Assemble the remaining parts of the cylinder and snap ring. piston in the opposite sequence to how they were To disassemble the cylinder disassembled. Refer to 5. Put a new cylinder base gasket on the crankcase. and piston on page 46 .
  • Page 50 3. Remove the cylinder cover. 5. Loosen, but do not remove, the 2 screws that hold the carburetor and air filter holder. Put a rubber sheet between the carburetor and the distance piece. Tighten the 2 screws. 4. Loosen the 3 screws that hold the muffler. Put a rubber sheet between the muffler and the cylinder.
  • Page 51: Crankshaft And Crankcase

    7.11 Crankshaft and crankcase 10. Remove the 4 screws (D) and the crankcase (E). 7.11.1 To disassemble the crankshaft and crankcase 1. Pull up the knob and remove the drive shaft tube. 2. Remove the throttle wire (A) from the throttle wire joint (B).
  • Page 52 12. Remove the screw (L) and remove the grass guard 16. Use a screwdriver or equivalent to remove the seal (M). ring from the crankcase halves. CAUTION: Remove the seal rings carefully. The crankcase is easily damaged. 17. Discard the seal ring. 18.
  • Page 53 19. Increase the temperature of the crankcase halves to b) On the starter side: Carefully tap on the bearing 120ºC with a hot air gun. removal tool with a rubber hammer until the bearing falls out. 20. Remove the bearings from the crankcase halves. a) On the flywheel side: Carefully tap on the bearing removal tool with a rubber hammer until the bearing falls out.
  • Page 54 7.11.2 To clean and examine the crankshaft and 7.11.3 To assemble the crankshaft and crankcase crankcase 1. Use snap ring pliers to attach the snap ring to the crankcase half on the flywheel side. The crankshaft cannot be repaired, replace it if it is worn or damaged.
  • Page 55 3. Attach the sealing rings. 5. Lubricate the crankshaft with some oil. Move the crankcase half on the clutch side into position. 4. Put the crankshaft in the crankcase half on the flywheel side. Lubricate the stub axle with some oil and carefully move the crankshaft into the bearing.
  • Page 56: Fuel Tank

    7. Attach the grass guard and muffler guard. 3. Remove the throttle wire (A) from the throttle wire joint (B). Remove the cables (C). 8. Assemble the remaining parts in the opposite sequence. 4. Turn the engine around its axle to access the air filter and carburetor.
  • Page 57 5. Remove the air filter cover and the air filter. 8. Remove the 4 screws and lift up the engine and fuel tank. 6. Remove the fuel hoses (A and B) from the air purge bulb. 9. Install the fuel tank in the opposite sequence. 7.
  • Page 58: Harness Frame

    7.13 Harness frame 7.12.2 To remove and install the fuel filter Note: To remove the fuel filter it is not necessary to 7.13.1 To disassemble and assemble the harness remove the fuel tank. frame 1. Pull up the knob and remove the drive shaft tube. 1.
  • Page 59: Handle And Throttle Trigger

    3. Remove the bolt (D), cable (E), washer (F) and the Remove the 2 stop screws (S) and its washers engine. and nuts, if it is necessary. 7.14 Handle and throttle trigger 7.14.1 To disassemble the throttle handle 1. Loosen the screws. 4.
  • Page 60 3. Push the front handle forward to remove the right 5. Remove the throttle trigger, link arm, springs and the handle half from the shaft. Examine the 4 vibration throttle lockout. damping units. Remove the vibration damping units and replace them, if it is necessary. 4.
  • Page 61: Gearbox

    7.14.2 To assemble the throttle handle 7.15.1 To disassemble the bevel gear (543RBX, 543RBK) 1. Put the cables and throttle wire in the correct positions. Make sure that the cables are attached to 1. Loosen the screw (A) and remove the splash guard.
  • Page 62 5. Remove the snap ring on the output shaft. 10. Tap the bevel gear against a wooden block to disassemble the input shaft. 6. Remove the snap ring (B) on the input shaft. 11. Lift the output shaft to remove it. 12.
  • Page 63 7.15.2 To assemble the bevel gear (543RBX) 5. Push out the output shaft into the gear housing. 1. Put the bevel gear and the output shaft together. Note: Make sure that the ball bearings touch the bottom of the gear housing.
  • Page 64 8. Put the input shaft in position with a pair of pliers. 11. Put grease into the gear through the grease filler cap Make sure that the bearing touches the bottom. (C) until it comes out through the valve (D). 9.
  • Page 65 4. Remove the snap ring (E) 9. Disassemble the bearings from the output and input shafts with a small bearing puller. 5. Remove the large snap ring that holds the ball bearing on the input shaft. 6. Use a hot air gun to increase the temperature of the full bevel gear to approximately 110°C.
  • Page 66 7.15.4 To assemble the bevel gear (543RBK) 1. Put the bearings on the related shafts. Use a hot air gun to increase the temperature of the bearings to approximately 110°C. 2. Install the bearings with the sealed side out. 3. Use a hot air gun to increase the temperature of the gearbox to approximately 110°C.
  • Page 67: 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.
  • Page 68 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.
  • Page 69 Increase and decrease speed The engine stops when the speed is de- The lever arm of the needle valve is too high. creased. 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 speed.
  • Page 70: Technical Data

    9 Technical data 543RBX 543RBK 553RBX Engine Cylinder displacement, cm 40.1 50.6 Cylinder bore, mm 40.5 45.5 Stroke, mm 31.1 31.1 Idle speed, rpm 3000 2800 Recommended max speed, rpm 12000 13000 Max. engine output, according to ISO 8893, 1.47 @ 9000 2.3 @ 9500...
  • Page 71 1239 - 001 - Technical data- 71...
  • Page 72 114 14 93-26 2019-09-27...

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