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Husqvarna 123HD60 Workshop Manual

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Workshop manual
123HD60 123HD65X
English

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  Summary of Contents for Husqvarna 123HD60

  • Page 1 Workshop manual 123HD60 123HD65X English...
  • Page 3 3. Fuel system ___________________________ 13 4. Centrifugal clutch _______________________ 25 5. Cutting deck ___________________________ 29 6. Cylinder and piston ______________________ 33 7. Crankshaft and crankcase ________________ 43 8. Tools _________________________________ 49 9. Technical Data _________________________ 53 © Husqvarna AB, Sweden 2010...
  • Page 4 Operator’s Manual. The assembly of other equipment or accessories or spare parts not approved by Husqvarna can Special tools result in the failure to meet these safety demands and that Some of the work described in the Workshop Manual requi- the person carrying out assembly bears responsibility for this.
  • Page 5 Starter Starter Contents Dismantling ___________________________________ 4 Assembly _____________________________________ 5 Replacing the drive _____________________________ 6...
  • Page 6 Starter WARNING! Protective glasses should be worn when working on the starter to avoid injury to the eyes if, for some reason, the return spring should fl y out. Dismantling Dismantling Remove the 4 bolts and lift off the starter. Remove the 4 screws and lift off the starter and the underlying guiding plate.
  • Page 7 Starter Assembly Assembly If the return spring has, despite all the Fit the return spring in the starter housing. precautions, fl own out or if you intend to fi t The pressure equalisation spring is sup- a new spring proceed as follows: plied as a spare part, fi...
  • Page 8 Starter Fit the starter handle. Fit the starter handle on the cord. Run the starter cord through the handle and make a knot in the starter cord. Pull the cord into the handle. Tighten the return spring. Tighten the return spring. Check the spring tension.
  • Page 9 Electrical system Electrical system Contents Checking the ignition spark ______________________ 8 Dismantling __________________________________ 11 Assembly __________________________________ 12...
  • Page 10 Electrical system The engine is equipped with an electronic ignition system completely without moving parts. Con- sequently, a faulty component cannot be repaired, but must be replaced by a new component. The spark in an electronic ignition system has a very short burn time and can therefore be inter- preted as weak and can be diffi...
  • Page 11 Electrical system If there is no spark, disconnect the short- If there is still no spark, separate the circuit contact . short-circuit cable which is accessible when the air fi lter cover is folded out of the Replace the contact if required. way.
  • Page 12 Electrical system Still no spark? Still no spark? Dismantle the fan housing cover with at- Dismantle the fan housing cover with at- tached starter. tached starter. Remove the 3 screws, lift off the plate (A) and then the cover. 502 50 18-01 Check other cables and connections.
  • Page 13 Electrical system Dismantling Dismantling Dismantle the following: The following components must be dismantled for the ignition system to be The cylinder cover, the spark plug, the accessible: fan housing cover with fi tted starter, the heat guard above the muffl er (A) and the The cylinder cover, the spark plug, the cylinder cover (B).
  • Page 14 Electrical system Remove the fl ywheel. Dismantle the fl ywheel from the crankcase using the puller no. 510 13 89-01. Gently knock the puller screw with a hammer, if the fl ywheel sits tightly on the crankshaft. 510 13 89-01 Assembly Assembly Check that the key and the key slot in the...
  • Page 15: Table Of Contents

    Fuel system Fuel system Contents Air fi lter _____________________________________ 14 Tank venting _________________________________ 15 Fuel fi lter ____________________________________ 15 Carburettor __________________________________ 16 Assembly ___________________________________ 20 Carburettor settings ___________________________ 20 Throttle handle _______________________________ 21 Trouble Shooting Guide ________________________ 23...
  • Page 16: Air Fi Lter

    Replace damaged fi lters with a new one. WARNING! Do not clean not the fi lter with petrol. Hazardous! TIP! Use Husqvarna’s cleaning agent Active Cleaning no. 505 69 85-70. 505 69 85-70 Impregnate the fi lter with air fi lter oil.
  • Page 17: Tank Venting

    Fuel system Tank venting Tank venting Check that the tank venting valve works Tank venting takes place through the fuel correctly. cap and needs to be functional for the engine to work. • Empty the fuel tank. • Remove the air fi lter cover. •...
  • Page 18: Carburettor

    Fuel system Carburettor Carburettor Dismantling Dismantling Remove the carburettor cover and the air 1. Remove the carburettor cover and the fi lter then blow clean around the carburet- air fi lter. 2. Close the choke valve and blow off Dismantle the throttle cable and fuel any dirt around the carburettor.
  • Page 19 Fuel system Tag bort de 4 skruvarna. Dismantle the fuel pump’s diaphragm and the valve housing. De är långa och håller ihop hela förgasa- ren. Lyft därefter bort bränslepumpens blåsa (A) och ventilhuset (B). Tag bort styrmembranet och inspektera det avseende materialskador och slitage på...
  • Page 20 Fuel system Check the lever arm and needle valve for Check the wear to the lever arm partly wear. by the contact points against the control diaphragm and partly by the cut-outs for Replace damaged parts with new parts. the needle valve. Also check wear to the tip of the needle valve and the groove for the lever arm.
  • Page 21 Fuel system Assembling the carburettor Assembling the carburettor Walbro WYL Clean and inspect all parts. Clean and inspect all parts. Worn or damaged parts are replaced Worn or damaged parts are replaced with with new ones. new ones. Pay attention to the following when the Pay attention to the following when the carburettor is assembled in the reverse carburettor is assembled in the reverse...
  • Page 22: Assembly

    Fuel system Assembly Assembly Check the distance piece for cracks. Inspect the distance piece (A) for cracks that can cause starting problems and neg- A defective distance piece must be re- ative idling. Check also that the impulse placed. channel (B) is open and not completely or Make sure that the impulse channel is partly blocked with grease, for instance, or entirely open.
  • Page 23: Throttle Handle

    Fuel system Throttle handle Throttle handle Dismantle the throttle cable (incl. the ad- 1. Dismantle the entire throttle cable from justment screw from the carburettor). the carburettor (incl. the adjustment screw). Separate the short-circuit cables and remove the lockwasher that holds the han- 2.
  • Page 24 Fuel system 8. Remove the throttle control (B), the throttle cable (C), the triangle link (D) and the stop switch (E). 9. Remove the screw (F) and detach and twist in the opposite direction the lock (G) that prevents handle rotation. Assemble the throttle handle in the re- verse order as set out for dismantling.
  • Page 25: Trouble Shooting Guide

    Fuel system Trouble Shooting Guide Symptom Starting Low speed Acceleration/ Deceleration Probable causes Stop screw for the throttle not working ● ● ● ● Fuel tank/hose Fuel fi lter blocked ● ● ● ● ● ● ● ● ● ● ●...
  • Page 26 Fuel system...
  • Page 27 Centrifugal clutch Centrifugal clutch Contents Centrifugal clutch, dismantling __________________ 26 Centrifugal clutch, assembling __________________ 27 Clutch drum ________________________________ 27...
  • Page 28 Centrifugal clutch The centrifugal clutch has the task of transferring the power from the engine to the cutting equipment’s drive axle. As the name implies, it works according to a centrifugal principle. This means the clutch’s friction shoes are thrown outwards towards the clutch drum at a certain engine speed.
  • Page 29 Centrifugal clutch Dismantle the clutch shoes from the hub. Dismantle the clutch shoes from the hub using a small screwdriver or a pointed tool. Check for wear on the friction lining. Check the friction linings for wear. The thickness must not be less than 1.3 mm. Replace worn or damaged components.
  • Page 30 Centrifugal clutch Remove the circlip and dismantle the ball Remove the circlip holding the ball bear- bearings. ings in place in the gear housing. Then heat the gear housing to approx. 110°C and tap the housing against a wooden block so that the ball bearing falls out of the bearing seating or use a suit- able mandrel.
  • Page 31 Cutting deck Cutting deck Contents Cutting deck, disassembly _____________________ 30 Cutting deck, assembly _______________________ 32...
  • Page 32 Cutting deck Cutting deck Cutting deck Dismantling Dismantling Disconnect the throttle cable and sepa- Unhook the throttle cable from the carbu- rate the connections on the short-circuit rettor and separate the connections to the cables. short-circuit cable. Remove the screws holding the engine to Remove the 4 screws holding the engine the vibrational dampers.
  • Page 33 Cutting deck Remove the crank rod (C), the sealing felt (D) and the cutting knives (E). Lift up the lower crank rod completely with sprocket and eccentric cam (F). This gives access to the screws (G) for dismantling the chain bar.
  • Page 34 Cutting deck Remove the circlip and pull the crank rod Remove the circlip and pull the crank rod over the eccentric cam. over the eccentric cam. See chapter entitled “Centrifugal clutch” for information on the small gear wheel . Assembly Clean and inspect all components for 531 00 92-05 wear and damage.
  • Page 35 Cylinder and piston Cylinder and piston Contents Dismantling __________________________________ 34 Cleaning, inspection ___________________________ 35 Analysis and actions __________________________ 36 Service tips _________________________________ 40 Wear tolerances _____________________________ 41 Assembly __________________________________ 41...
  • Page 36: Dismantling

    Cylinder and piston The cylinder and the piston are two of the components exposed to most strain in the engine. They must withstand, for example, high speeds, large temperature swings and high pressure. Moreover, they must be resistant to wear. Despite these tough working conditions, major piston and cylinder failure is relatively uncommon.
  • Page 37: Cleaning, Inspection

    Cylinder and piston Remove the circlips from the gudgeon pin. Remove the circlips on the gudgeon pin using a small fl at nosed pliers. Keep your thumb over the circlip to pre- vent it from fl ying out. Dismantle the piston. Push the gudgeon pin from the piston using punch 505 38 17-05.
  • Page 38: Analysis And Actions

    Blocked spark arrestor mesh in the Clean or replace the spark arrestor mesh. muffl er. For the best results we recommend Husqvarna two-stroke oil or ready-mixed fuel that is specially developed for air-cooled two-stroke engines. Mixing ratio: 1:50 (2%). If Husqvarna two-stroke oil is not available another good quality two-stroke oil can be used.
  • Page 39 Cylinder and piston Piston scoring caused by heavy carbon deposits Too heavy carbon depositing can cause damage similar to that caused by insuffi cient lubrication. However, the piston skirt has a darker colour caused by the hot combustion gases that are blown past the piston. This type of piston damage starts at the exhaust port where carbon deposits can be- come loose and get trapped between the piston and the cylinder wall.
  • Page 40 Cylinder and piston The guide pin for the piston ring has been Deep, irregular grooves caused by a loose Irregular grooves on the piston’s inlet side pushed up through the top of piston. circlip. Shown here on the piston’s inlet side. caused by a broken roller retainer.
  • Page 41 Cylinder and piston Cause: Action: • Faulty air fi lter. Small dust particles Fit a fi ner grade fi lter. pass through the fi lter. • The fi lter is worn out due to too much Check the fi lter carefully for holes and cleaning, whereby small holes have damage after cleaning.
  • Page 42: Service Tips

    Cylinder and piston Larger, harder particles that enter the engine cause serious damage to the underside of the piston skirt. Cause: Action: • Air fi lter damaged or missing. Fit a new air fi lter. • Parts from the carburettor or intake Regular service and inspection.
  • Page 43: Wear Tolerances

    Cylinder and piston Wear tolerances Piston ring gap Piston ring groove Piston ring play Cylinder bore When the surface coating is Max. 1.0 mm with the piston Max. 1.6 mm. Clean the groove Max. 0.15 mm. Clean the groove worn and aluminium appears. ring inserted in the lower part of before checking the measure- before checking the measure-...
  • Page 44 Cylinder and piston Inspect the distance piece for crack forma- tion or other damage that may result in leakage, which in turn can cause uneven idling and starting diffi culties. Check that the impulse channel (A) is open all the way through the gaskets and the heat protective plate to the cylinder.
  • Page 45 Crankshaft and crankcase Crankshaft and crankcase Contents Dismantling ________________________________ 44 Inspecting the crankshaft ______________________ 45 Assembly _________________________________ 46...
  • Page 46 Crankshaft and crankcase The task of the crankshaft is to transform the reciprocating motion of the piston to rotation. This requires a stable design withstanding immense pressure and rotational and bending strain, as well as high rotational speed. In addition the connecting rod is exposed to large acceleration and retardation forces as it moves between the top and bottom dead centres.
  • Page 47 Crankshaft and crankcase Lift the crankshaft out of the crankcase Dismantle the ball-bearings from the half on the starter side (a special tool is crankcase halves. not required). Heat the crankcase halves to 120°C using a hot air gun. Knock the crankcase half against a woo- Knock the crankcase half against a woo- den block so that the ball-bearing falls out.
  • Page 48 Crankshaft and crankcase Inspect the small end of the connecting Inspect the small end of the connecting rod. rod. If seizure marks or discolouration are found in the bearing track the crankshaft must be replaced. Check the crank bearing. Check the crank bearing. The connecting rod shall not have any radial play (up and down).
  • Page 49 Crankshaft and crankcase Fit the crankshaft in the crankcase half on Fit the crankshaft in the crankcase half on the fl ywheel side. Lubricate the stub axle the fl ywheel side. with a few drops of oil and carefully slide the crankshaft into the bearing.
  • Page 50 Crankshaft and crankcase...
  • Page 51 List of tools Tools Contents Starter __________________________________ 50 Electrical system __________________________ 50 Fuel system ______________________________ 50 Centrifugal clutch __________________________ 51 Cutting deck _____________________________ 51 Cylinder and piston ________________________ 51 Crankshaft and crankcase ___________________ 51 Workshop equipment _______________________ 51...
  • Page 52 List of tools 502 50 18-01 510 13 89-01 505 69 85-70 502 51 91-01 501 60 02-03 502 50 19-01 502 71 13-01 531 00 60-76 502 50 06-01 522 43 18-01 531 03 06-23 502 50 83-01 502 50 18-01 502 50 19-01 502 51 34-02 502 02 61-02...
  • Page 53 List of tools 502 50 18-01 531 00 92-05 502 50 18-01 502 50 18-01 544 13 05-01 502 50 23-01 505 38 17-05 503 26 72-01 544 13 08-01 522 43 18-01 505 38 13-08 505 38 13-08 502 50 70-01 502 50 70-01 544 13 09-01 576 95 40-01...
  • Page 54 List of tools...
  • Page 55 Technicel data Technical data Contents Engine __________________________________ 54 Ignition system ____________________________ 54 Carburettor ______________________________ 54 Clutch __________________________________ 54 Cutting equipment _________________________ 54 Dimensions ______________________________ 54...
  • Page 56 Technicel data Engine 123 HD60 123 HD65X Displacement, cm 22.5 22.5 Cylinder bore, mm 32.0 32.0 Stroke, mm 28.0 28.0 Engine output, kW / speed, rpm 0,6/7000 0,6/7000 Catalytic converter muffl er Ignition system Spark plug NGK BPMR 6Y NGK BPMR 6Y Electrode distance, mm Electronic speed limitation Carburettor...
  • Page 58 115 39 91-26 2010W40...

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123hd65x