Husqvarna 522HS75S Workshop Manual
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Husqvarna 522HS75S Workshop Manual

Husqvarna 522HS75S Workshop Manual

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Workshop manual
522HS75S
English
1008 - 003 - 24.11.2020

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Summary of Contents for Husqvarna 522HS75S

  • Page 1 Workshop manual 522HS75S English 1008 - 003 - 24.11.2020...

  • Page 2: Table Of Contents

    Contents 1 Introduction 1.1 Document description..........3 1.2 Target group............3 1.3 Revisions..............3 1.4 Safety..............3 1.5 Servicing tools............3 2 Safety 2.1 Safety definitions............4 2.2 General safety instructions........4 2.3 Symbols on the product......... 4 3 Prepare and do servicing on the product 3.1 Maintenance schedule...........

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1008 - 003 - 24.11.2020 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions High speed needle. Warnings, cautions and notes are used to point out specially important parts of the manual. WARNING: Used if there is a risk of injury or Low speed needle. 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 Maintenance Before After 100 After 40 h operation Clean the external surface. After each operation. Clean the muffler, exhaust pipe and engine from leaves, dirt and unwanted lubri- After each operation. cant.

  • Page 6: Servicing Data

    4 Servicing data 4.1 Servicing data ▲ Lubricate with 2-stroke oil. ● Lubricate with grease. 3 - 4 Nm 6 - 8 Nm 14 mm 2 - 3 Nm 3 - 4 Nm 1.5 - 2.5 Nm 5 - 8 Nm 2 - 3 Nm 3 - 4 Nm 7 - 9 Nm...
  • Page 7 6 - 8 Nm 3 - 5 Nm 6 - 9 Nm 4 - 6 Nm 10 - 15 Nm 6 - 9 Nm 8 mm 1008 - 003 - 24.11.2020 Servicing data - 7...
  • Page 8 14 - 16 Nm 4 - 6 Nm 13 mm 3 - 4 Nm 6 - 8 Nm 8 - 10 Nm 10 - 12 Nm 6 - 8 Nm 16 mm 2.5 - 3 Nm 1.5 - 2.5 Nm 4.5 - 5.5 Nm 3 - 4 Nm 10 - 12 Nm...
  • Page 9 6 - 9 Nm 8 mm 6 - 9 Nm 8 mm 3 - 5 Nm 6 - 9 Nm 3 - 5 Nm 1008 - 003 - 24.11.2020 Servicing data - 9...

  • Page 10: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 10 - Servicing tools 1008 - 003 - 24.11.2020...
  • Page 11 Item Description Use for Article number Piston stop To lock the crankshaft 521 54 83-01 Hook for fuel filter To remove the fuel filter 502 50 83-01 T-handle Torx For Torx screws 502 71 31-01 Piston assembly kit To assemble the piston 502 50 70-01 Air gap tool To measure the distance between the...

  • Page 12: Function Overview

    6 Function overview 6.1 Type plate and product serial number 12 - Function overview 1008 - 003 - 24.11.2020...

  • Page 13: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 1. Starter unit 13. Crankcase and crankshaft 2. Muffler 3. Spark plug 7.2 To clean and examine the product parts 4. Flywheel • Clean and examine all parts fully. You find more 5.

  • Page 14: Starter

    7.3 Starter 3. Let the pulley rotate slowly rearward to release the tension of the recoil spring. 7.3.1 To disassemble the starter unit 1. Remove the 4 screws and remove the starter unit. 4. Remove the bolt (A) and washer. Carefully remove the starter pulley (B) together with the recoil spring (C).
  • Page 15 4. Lubricate the recoil spring and the stub axle of the starter pulley with Husqvarna grease. 5. Put the starter rope through the opening (H) in the starter housing. Put the starter pulley in position. Put the free end of the recoil spring into the notch (I) on 2.
  • Page 16 6. Put the starter rope handle on the starter rope. 8. Pull the starter rope to make it straight, remove your thumb and let the starter rope wind up. 7. Pull the starter rope up into the notch in the starter pulley.

  • Page 17: Muffler

    7.4 Muffler 7.5 Air filter 7.4.1 To disassemble the muffler 7.5.1 To disassemble the air filter 1. Remove the 2 screws and remove the muffler cover. 1. Pull the clips (A) to the side to release the air filter cover (B). The air filter cover is connected to the air 2.

  • Page 18: Flywheel

    7.6 Flywheel 5. Remove the nut that holds the flywheel. 7.6.1 To disassemble the flywheel 1. Clean around the spark plug. 2. Remove the spark plug cap and the spark plug. 3. Put a piston stop in the spark plug hole. 6.
  • Page 19 8. Remove the locking washers (A) with a screwdriver. 7.6.3 To assemble the flywheel This causes deformation of the 2 washers. Discard 1. Make sure that the key in the flywheel and keyway in the 2 washers. the crankshaft are not damaged. 2.

  • Page 20: Ignition System

    4. Install the flywheel and attach the nut. Remove the 6. Install the starter unit. piston stop. 5. Put the air gap tool between the flywheel and the Servicing tools on page 10 ignition module. Refer to for the correct distance. 7.
  • Page 21 • If the spark plug is dirty, clean it and make sure that 7.7.4 To do a test of the short circuit cable Technical data the electrode gap is correct, refer to • If there is no spark, disconnect the short circuit on page 52 .
  • Page 22 7.7.5 To examine the spark plug cable 4. Put the end of the cable against the stop of the Servicing tools on page 10 . assembly pliers, refer to If there is no spark, do the procedure that follows to Then close the pliers to make the new hole.
  • Page 23 8. Push the cable into the spark plug cap. 7.7.6 To examine the ignition module If there is no spark, do the procedure that follows to examine the connection between the spark plug cable and the spark plug. 1. Remove the starter unit. 9.
  • Page 24 3. Examine the distance between the flywheel magnet 7.7.7 To remove the ignition module and the ignition module with an air gap gauge. Refer 1. Remove the starter unit. Servicing data on page 6 for the correct distance. 4. Adjust the distance, if it is necessary. Loosen the screws and adjust the ignition module until the distance is correct.
  • Page 25 5. Remove the screws and cable (B). Pull up the 7.7.8 To install the ignition module ignition module and spark plug cable. 1. Attach cable (A) to the ignition module. Put the module in the crankcase. Attach the 2 screws and cable (B).

  • Page 26: Carburetor

    3. Adjust the distance. Tighten the screws when the 5. Install the starter unit. distance is correct. 4. Make sure that the cables are in their correct position. 6. Install the spark plug and the spark plug cap. 7.8 Carburetor 7.8.1 To disassemble the carburetor 1.
  • Page 27 3. Remove the 2 screws. Remove the air filter holder. 6. Remove the 4 screws (F). Note: The carburetor is only attached to the fuel hoses (D) and (E), the transparent hose and the throttle wire (C). 4. Make a note of the positions of the gaskets (A) and (B) as they can easily fall off.
  • Page 28 11. Examine the wear to the lever arm and the needle 7.8.3 To assemble the carburetor valve. 1. Examine that the lever arm is flush with the carburetor housing without a gasket. 12. Carefully lift up check valve (N). 2. Assemble the carburetor parts. 13.
  • Page 29 3. Examine that the carburetor is sealed. 7. Attach the air filter. 8. Close the air filter cover with the clips. a) Connect a pressure tester to the fuel inlet on the 7.8.4 To adjust the carburetor settings carburetor. Pump up the pressure to 50kPa. To adjust the carburetor means that you adjust the b) Lower the carburetor in a container with gasoline engine to the local conditions such as weather, altitude...

  • Page 30: Handle And Throttle Trigger

    To adjust the carburetor settings on settings, refer to handle but not replace the throttle wire, start the page 29 . procedure at step 3. 1. Remove the 2 screws, the throttle wire cover and the throttle wire from the carburetor. Basic factory settings H = high speed jet L = low speed jet...

  • Page 31: Clutch, Clutch Drum And Gearbox

    3. Remove the 3 screws and 1 nut. 11. Remove the transparent fuel hose from the carburetor. 12. Use pliers to open the clamp and remove the fuel hose from the fuel tank. CAUTION: Be careful when you disassemble. The inner parts of the handle can easily fall out.
  • Page 32 4. Remove the 3 screws (A). 9. Remove the clutch shoes from the hub with a small screwdriver. CAUTION: Use rubber brackets in the vise to prevent damage to the clutch. 10. Remove the 6 screws and remove the gearbox cover.
  • Page 33 11. Remove the gasket (A). 22. Put the clutch drum in the thread holes in the gearbox housing to lock in position. Use a gear drive removal tool to remove the gear drive. Refer to Servicing tools on page 10 . 23.

  • Page 34: Cutting Equipment

    7.10.3 To assemble the clutch, gearbox and clutch drum Install the clutch shoes with the text on the clutch shoes visible. 1. Use approximately 20 g of grease to lubricate all Servicing data on page 6 . parts. Refer to 2.
  • Page 35 7.12.2 To remove the cylinder and piston 3. Remove the cylinder cover. 1. Remove the 2 screws, the throttle wire cover and throttle wire. 4. Remove the heat shield, if it is attached. 2. Remove the 4 screws, the manifold and the gasket. 1008 - 003 - 24.11.2020 Repair instructions - 35...
  • Page 36 5. Remove the 2 screws, the cylinder and the cylinder 6. Remove the snap rings on the piston pin with a base gasket. Put a cloth above the crankcase small flat nose pliers. Hold your finger on the snap opening below the piston. ring to make sure it does not eject.
  • Page 37 9. Remove the piston ring, if it is necessary. • Use a screwdriver to remove dirt particles from the cooling fins. 7.12.3 To clean and examine the cylinder and piston CAUTION: Clean carefully. The soft aluminum part are easily damaged. •...
  • Page 38 • Put the piston ring in the cylinder and measure the • Clean and examine the piston ring groove. It must space with an air gap tool. The space must not be not be more than 1.6 mm. more than 1 mm. •...
  • Page 39 7.12.6 To assemble the cylinder and piston 5. Put a new cylinder base gasket on the crankcase. 1. Lubricate the needle bearing with two-stroke oil and put it into the connecting rod. Make sure the bearing moves freely in the connecting rod. CAUTION: Make sure that the cylinder base gasket does not have signs of damage and wear.

  • Page 40: Crankshaft And Crankcase

    7. Use the clamp from the piston assembly kit to 7.13.2 To disassemble the crankcase and compress the piston ring. Carefully push the piston crankshaft into the cylinder opening. Tighten the 2 screws to 1. Remove the 3 screws and disconnect the crankcase Servicing data on page the specified torque.
  • Page 41 4. Use a screwdriver or equivalent to remove the a) Flywheel side. sealing ring from the crankcase halves. CAUTION: Remove the sealing rings carefully. The crankcase is easily damaged. a) Flywheel side. b) Clutch side. b) Clutch side. 5. Discard the sealing ring. 6.
  • Page 42 7. Increase the temperature of the crankcase halves to b) Clutch side. 120ºC with a hot air gun. To get 8. Use a ball bearing removal tool, refer to access to the crankcase and crankshaft on page 40 , to remove the bearings from the crankcase halves. a) Flywheel side.
  • Page 43 • Examine the crankshaft bearing. There must be no b) Clutch side. radial play in the connecting rod. Make sure that there is axial play to sufficiently lubricate the crankshaft bearing. • Examine the crankcase halves for cracks and damages. 7.13.4 To assemble the crankcase and crankshaft 1.
  • Page 44 b) Clutch side. 4. Put the crankshaft in the crankcase half on the flywheel side. Lubricate the stub axle with some drops of oil and carefully move the crankshaft into the bearing. 3. Put the sealing ring in the crankcase half on the flywheel side.
  • Page 45 5. Install the gasket to the clutch side of the crankcase 6. Put an assembly sleeve on the crankshaft on the half. Lubricate the crankshaft pin with some drops of clutch side to prevent damage to the sealing ring. oil and move the crankcase half on the clutch side Lubricate the crankshaft with oil and install the into position.

  • Page 46: Fuel Tank

    7.14 Fuel tank 7.14.2 To remove the fuel tank 1. Drain the fuel tank and put the product with the top 7.14.1 To do a tank venting down. 1. Drain the fuel tank and put the product with the top 2.
  • Page 47 7.14.3 To clean and examine the fuel filter 6. Put the fuel filter in the tank as shown in the illustration. 1. Remove the fuel tank cap. 2. Pull the fuel hose and the fuel filter from the fuel tank with a hook.

  • Page 48: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting Starting The engine is hard 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 The control diaphragm is damaged The control diaphragm has a defective seal...
  • Page 49 Idle speed (low speed) The idle speed does not become The stop screw for the throttle does not operate correctly stable Blocked fuel filter Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel The needle valve is defective The carburetor is not attached correctly The lever arm of the needle valve does not operate correctly The needle valve spring is not attached correctly The control diaphragm is damaged...
  • Page 50 High speed Unsatisfactory performance at Blocked fuel filter high speed Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel Vacuum pulse leakage Blocked vacuum pulse pipe Loose screws on the pump cover Defective pump diaphragm The needle valve is defective The carburetor is not attached correctly The lever arm of the needle valve is damaged The lever arm of the needle valve does not operate correctly...
  • Page 51 Increasing and decreasing speed Can not increase speed Defective heat insulation seal 1008 - 003 - 24.11.2020 Troubleshooting - 51...

  • Page 52: Technical Data

    9 Technical data 9.1 Technical data 522HS75S Engine Cylinder displacement, cu.in/cm 1.32/21.7 Idle speed, rpm 3000 Recommended max speed, rpm 9200 Maximum engine power acc. to ISO 8893, kW/hp @ rpm 0.6/0.8 @ 7800 Catalytic converter muffler Ignition system Spark plug...
  • Page 53 1008 - 003 - 24.11.2020 Technical data - 53...
  • Page 54 54 - Technical data 1008 - 003 - 24.11.2020...
  • Page 55 1008 - 003 - 24.11.2020 Technical data - 55...
  • Page 56 1141155-26 2020-11-30...

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