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Husqvarna 522HDR75S Workshop Manual

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Workshop manual
522HD60S, 522HDR60S,
522HDR75S
English
1017 - 002 - 25.11.2020

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Summary of Contents for Husqvarna 522HDR75S

  • Page 1 Workshop manual 522HD60S, 522HDR60S, 522HDR75S English 1017 - 002 - 25.11.2020...

  • 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. 1017 - 002 - 25.11.2020 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 2 - 3 Nm 5 - 8 Nm 4 - 5 Nm 2 - 3 Nm 2 - 3 Nm 5 - 7 Nm 4 - 5 Nm 3 - 4.5 Nm 3 - 4.5 Nm...
  • Page 7 6 - 8 Nm 3 - 5 Nm 6 - 9 Nm 4 - 6 Nm 10 - 15 Nm 6 - 9 Nm 8 mm 1017 - 002 - 25.11.2020 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 522HD60 6 - 9 Nm 6 - 9 Nm 8 mm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 3 - 5 Nm 3 - 5 Nm 1017 - 002 - 25.11.2020 Servicing data - 9...
  • Page 10 522HDR60 6 - 9 Nm 6 - 9 Nm 8 mm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 3 - 5 Nm 3 - 5 Nm 10 - Servicing data 1017 - 002 - 25.11.2020...
  • Page 11 522HDR75 6 - 9 Nm 6 - 9 Nm 8 mm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 8 mm 6 - 9 Nm 3 - 5 Nm 3 - 5 Nm 1017 - 002 - 25.11.2020 Servicing data - 11...

  • Page 12: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 12 - Servicing tools 1017 - 002 - 25.11.2020...
  • Page 13 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 14: Function Overview

    6 Function overview 6.1 Type plate and product serial number 14 - Function overview 1017 - 002 - 25.11.2020...

  • Page 15: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 1. Starter unit 13. Crankcase and crankshaft 2. Muffler 14. Vibration damping system 3. Spark plug 4. Flywheel 7.2 To clean and examine the product parts 5. Ignition module • Clean and examine all parts fully. You find more 6.

  • Page 16: 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 17 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 18 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 19: 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 20: 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 21 7. Remove the locking washer (A) with a screwdriver. 7.6.3 To assemble the flywheel This causes deformation of the washer. Discard the 1. Make sure that the key in the flywheel and keyway in washer. the crankshaft are not damaged. 2.

  • Page 22: 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 data on page 6 ignition module. Refer to for the correct air gap. 7.
  • Page 23 • 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 1. Remove the 2 screws and remove the handle cover. on page 56 .
  • Page 24 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 12 . 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 25 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 26 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 27 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 28: 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 29 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 30 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 31 3. Examine that the carburetor is sealed. 7. Attach the air filter. 8. Close the air filter cover with the clips. 7.8.4 To adjust the carburetor settings a) Connect a pressure tester to the fuel inlet on the carburetor. Pump up the pressure to 50kPa. To adjust the carburetor means that you adjust the engine to the local conditions such as weather, altitude b) Lower the carburetor in a container with gasoline...

  • Page 32: Handle And Throttle Trigger

    To adjust the carburetor settings on 7.9 Handle and throttle trigger settings, refer to page 31 . 7.9.1 To disassemble the handle 1. Use a pair of pliers to bend open the cable holder and remove the throttle wire from the cable holder. Basic factory settings H = high speed jet L = low speed jet...
  • Page 33 3. Remove the 2 screws and remove the handle cover. 5. Make a note of the plug (B) on the handle. Pull the safety catch (A) rearward and rotate the handle. 4. Disconnect the short circuit cables. 6. Push out the safety catch (C) with a small screwdriver to make the plug (B) go through.
  • Page 34 7. Open up the lock tab (D) with a very small flat 9. Remove the safety catch (E) and remove the spring screwdriver. Pull out the handle. (F) from the safety catch. 10. Remove the throttle wire from the throttle trigger. Make a note of the position of the throttle wire.

  • Page 35: Clutch, Clutch Drum And Gearbox

    7.10 Clutch, clutch drum and gearbox 11. Remove the handle parts. Make a note of the position of the spring. 7.10.1 To disassemble the clutch, clutch drum and gearbox 1. Remove the spark plug. 2. Put a piston stop in the spark plug hole. To disassemble the 3.
  • Page 36 7. Use the clutch removal tool to remove the clutch. 10. Remove the 6 screws and remove the gearbox Servicing The clutch has a left hand thread. Refer to cover. Use a flat screwdriver if it is necessary. tools on page 12 . 8.
  • Page 37 13. Remove the seal (C). CAUTION: Replaced or cleaned parts must 14. Remove the connecting rod (D). be lubricated on all sides. Use Husqvarna Servicing tools bevel gear grease. Refer to 15. Remove the 2 screws (E) and the nuts (F).

  • Page 38: 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 39 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. 1017 - 002 - 25.11.2020 Repair instructions - 39...
  • Page 40 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 41 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 42 • 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 43 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 44: 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 45 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 46 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 44 , to remove the bearings from the crankcase halves. a) Flywheel side.
  • Page 47 • 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 48 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 49 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 50: 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 51 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 52: 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 53 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 54 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 55 Increasing and decreasing speed Can not increase speed Defective heat insulation seal 1017 - 002 - 25.11.2020 Troubleshooting - 55...

  • Page 56: Technical Data

    9 Technical data 9.1 Technical data 522HD60S 522HDR60S 522HDR75S Engine Cylinder displacement, cm 21.7 21.7 21.7 Idle speed, rpm 3000 3000 3000 Recommended max speed, rpm 9200 9200 9200 Maximum engine power, acc. to ISO 8893, 0.6/0.8 @ 7800 0.6/0.8 @ 7800 0.6/0.8 @ 7800...
  • Page 57 1017 - 002 - 25.11.2020 Technical data - 57...
  • Page 58 58 - Technical data 1017 - 002 - 25.11.2020...
  • Page 59 1017 - 002 - 25.11.2020 Technical data - 59...
  • Page 60 114 11 54-26 2020-11-30...

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