Husqvarna 165 R Workshop Manual

Clearing saw
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  Summary of Contents for Husqvarna 165 R

  • Page 2 Technical data Service data Special tools Fuel system, carburettor Electrical system Cylinder, piston Crankcase, crankshaft Starter Handlebars, controls Engine mounting, drive shaft Transmission system...
  • Page 3: Fuel Tank Capacity

    Shaft angle Weight 10.8kg Empty clearing saw without harness and transit protection for saw blade Grease EP 0 grease or Husqvarna special grease, order number 502 51 27-01 Classification table Cylinder class Piston class If absolutely necessary, a class A piston may be used with a class B cylinder.
  • Page 4: Leakage Testing

    Leakage testing Pressure: 0.08 MPa (0.8 kgf/cm Max. leakage: 0.02 MPa per 30 see (0.2 kgf/cm2 per 30 sec. ) Tools: 502 50 38-01 Pressure tester 502 50 45-01 Spacer sleeve (35 mm) 502 50 47-01 Sealing plate, inlet 502 50 48-01 Sealing plate, exhaust Starter It should be possible to turn the cord pulley about another half-turn when the starter cord 15 fully with-...
  • Page 5: Fuel Mixture

    For premixed two-stroke oil a mixture of 1 part oil to 20 parts petrol (5%) is recommended. For Husqvarna Two-stroke Oil a mixture of 1 part oil to 50 parts petrol (2%) is recommended. The table below shows the different mixture proportions.
  • Page 7 502 50 06-01 502 50 37-01 Pliers, sparking Vacuum tester, complete plug cover 502 50 18-01 NV 4 mm 502 50 18-01 NV 3 mm 502 50 64-01 NV 5 mm T-type Allen key 502 50 38-01 Pressure tester, complete 502 50 42-01 Lithium grease, 250 g 502 50 20-01 (M5)
  • Page 8 502 50 50-01 Repair kit for electric leads 502 50 78-01 Extractor, sealing ring 502 50 79-01 Sealing ring assembly sleeve 502 50 51-01 Crimping pliers 502 50 83-01 Hook for tank weight 502 50 53-01 Sealing ring assembly socket 502 50 86-01 NV 3 mm 502 50 87-01 NV 4 mm 502 50 88-01 NV 5 mm...
  • Page 9 502 51 06-01 Glue 502 51 07-01 Epoxy adhesive 502 51 08-01 Loctite AA (normal locking force) 502 51 09-01 Loctite AAV (high locking force) 502 51 24-01 SEM ignition system tester 502 70 04-01 (M12) Screw for puller...
  • Page 10: Dismantling The Carburettor

    Dismantling the carburettor Clamp the cleanse saw in fixture No 502 51 03-01. Back off the four screws holding the diaphragm cover in Remove the cylinder casing and blow as much dirt as place and remove the cover Remove the diaphragm possible away from the area round the carburettor, Note that the centre stud of the diaphragm enters a using compressed air...
  • Page 11 Drill a small hole (diameter approx 2 mm) in the two B. Metering system blank plugs and pose the plugs out by means of a sharp Check that the adjusting screws are straight and that no object tip is broken. Inspect the cones for damage.
  • Page 12: Assembling The Carburettor

    Assembling the carburettor The needle valve lever must not be worn either at the needle valve end or the diaphragm end (see Fig 4:11) A. Pump Check that the filter screen at the main Jet is neither Carefully fit the fuel filter back in place. dirty nor damaged Check that it is the right way round with the flared collar upwards.
  • Page 13 When correctly adjusted. the needle valve lever should Connect the fuel line and check that it has no kinks that may interrupt the supply of fuel. be on a level with the carburettor housing (see Fig. Fit the air cleaner in place. 4:14) The lever can be adjusted by bending the forked end up or down (press the needle valve down at the same time).
  • Page 14 Run the engine at maximum speed by holding the throttle control firmly open if the setting is correct the engine should "four-stroke" Reduce engine speed by slowly screwing in H needle until fourstroking ceases From this position back it off corresponding to ten minutes on a clock face If a tachometer such as No 502 50 36 01 is available do not allow the engine to race at more than 11200 r/min...
  • Page 16: Fault Tracing

    A. Fault tracing A1 Dismantle the cylinder casing and remove the spar- king plug. Reconnect the plug lead and rest the sparking plug against ''earth'' e g the cylinder. Check whether a spark occurs between the elec- trodes when the engine is turned over by means of the starter.
  • Page 17 Fit puller No 502 50 26-01 to the holdfast and withdraw the flywheel NOTE: Rest the flywheel on a clean surface to avoid metal Sunny or metal objects hero attracted to the magnets. Connect the module to the instrument as shown in Fig.
  • Page 18 spacer. Exercise care on assembly to avoid damaging the lead. After flitting the armature plate n the crankcase it will be necessary to set the timing, Rotate the plate until the mark on the crankcase and the line inscribed on the ar- mature plate are opposite each other (ignition system SEM G6/35E see Fig.
  • Page 19 Dismantling Empty the fuel tank. Clamp the clearing saw in fixture No 502 51 03-01. Remove the cylinder casing and clean the cooling fins of the cylinder as well as the area round the cylinder base. Also clean the carburettor and spacer, making sure they are free from metal filings and dirt.
  • Page 20 inspection FAULT REMEDY Broken cooling fins In serious cases - change the cylinder Damaged threads Repair the threads with Heli-Coll inserts. Binding marks in cylinder wall (particularly Clean the damaged area with One emery cloth to remove at exhaust pod) adhering aluminium in the case of deeper binding scrat- ches the cylinder and piston should be replaced Surface...
  • Page 21 Rotate the crankshaft to check that the piston can move freely, Secure the cylinder by tightening the four screws alter- nately. Fit the silencer in place. Do not forget the securing plate for the screws in the cylinder nor the two screws holding the bottom of the silencer to the crankcase.
  • Page 22 Dismantling the crankcase Empty the fuel tank. Clamp the clearing saw in fixture No 502 51 03-01. Remove the following. Cylinder casing, starter carburettor cylinder and piston. The throttle control cable need not be removed. Back off the three screws securing the sealing ring hol- der and remove the holder.
  • Page 23: Inspection Of Crankshaft

    Inspection of crankshaft The crankshaft cannot be reconditioned and must be re- placed by a new one in the event of defects or damage. Some crankshafts display slight blue discolouration of the webs round the crank pin. This is perfectly normal and is the result of heat treatment round the crank pin hole.
  • Page 24 Check that the sealing rings are not worn or otherwise damaged (cracks in the rubber) and fit replacements if necessary. Lubricate the sealing rings with off before fitting them in place. Use sealing ring assembly sleeve No 502 50 79-01. Check that the crankshaft is free to rotate easily.
  • Page 25 Remove the return spring from the starter housing by turning the housing so that the spring faces the work- bench Pull the spring out of the housing, using a suitable pair of pliers. Remove the starter. Relieve the return spring tension by withdrawing the starter cord about 30 cm securing it in the notch in the periphery of the pulley and allowing the pulley to rotate slowly backwards (braking it with your thumb).
  • Page 26 Wind all the starter cord round the pulley, making sure that the pulley does not rotate. Pull the cord all the way out, braking the cord pulley with your thumb Wind the cord about another two turns round the pulley. Checking Pull the starter cord all the way out.
  • Page 27: Adjusting The Handlebars

    Adjusting the handlebars The left-hand and right-hand halves of the handlebars can be adjusted to any desired position after slackening the five screws in the clamp and then the locking screw underneath. After adjustment, first tighten the five screws in the clamp and finally the locking screw under- neath Back off screws A and B.
  • Page 28 Adjusting the spring tension of the throttle control Fig 9:4 Back off screw B about 1-11/2 turns. Grip sleeve C with a pair of pliers. Slacken stop screw D and hold the throttle control firmly. Rotate sleeve C in the direction of the arrow to increase the spring tension.
  • Page 29 Engine unit - drive shaft Apply a few drops of Loctite to the screws and tighten the engine to the clutch housing. Dismantling NOTE: ins extremely important to ensure that the four screws are properly tightened . Connect the short-circuiting cable to the stop contact. Fit the cylinder casing in place.
  • Page 30 Assembly Fit new dampers and check that the locating stud in the clutch housing fits into the hole in the vibration damper. Slide the suspension tube onto the drive tube but Fit the suspension tube and clutch housing together do not tighten the clamping screw. (see "Assembly"...
  • Page 31 Inspect the drive tube for damage. Dents in the tube (after a kickback for example) may cause the driveshaft to bind in the bearings. This may give rise to vibration and in the worst case seizure of the bearings. Assembly Assemble the drive shaft tube in reverse order to dismantling NOTE: Its extremely important to ensure that the drive...
  • Page 32 Centrifugal clutch, drive shaft Check that the clutch spring is not broken or discoloured by running hot. If it is, change the spring. Separate the engine unit the clutch housing (see section 10). Remove the drive shaft with clutch drum from the drive shaft tube.
  • Page 33 Removal of lower bearing housing When fitting new spring, check that its engagement point is opposite a centrifugal weight. and gear shaft Do not overload the spring on assembly. Angle gear Dismantling Mount the clearing saw in fixture No. 502 5103-01. Heat the angle gear with a blowlamp to approx t 30°C.
  • Page 34 Replacement of lower gear shaft Fit extractor No 502 50 63-01. Heat the gear housing with a blowlamp to about 1 30º C. Clamp the gear housing in a vice. Press the gear shad out of the bearing housing. Quickly press the being housing in all the way. Check the condition of the ball bearings and replace if Leave the puller in place until the gear housing has cool- necessary.
  • Page 35 After carrying out work on the angle gears they must be lubricated. Remove the filler plug and use not more than 15 grams/ ½ ounce of the special Husqvarna grease – type EP O - part no. 502 51 27-01, or one of the recommended lubricants hated below.