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Husqvarna 543RS Workshop Manual
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Husqvarna 543RS Workshop Manual

Husqvarna 543RS Workshop Manual

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Workshop manual
543RS & 553RS
English
1152 - 001 -

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Summary of Contents for Husqvarna 543RS

  • Page 1 Workshop manual 543RS & 553RS English 1152 - 001 -...
  • Page 2 2.5 Symbols on the product......... 4 3 Prepare and do servicing on the product 3.1 Maintenance schedule........... 6 3.2 Assembly..............6 4 Servicing data 4.1 Servicing data (543RS).......... 8 4.2 Servicing data (553RS)........11 5 Servicing tools 5.1 Servicing tools............14 6 Repair instructions 6.1 Product overview for repair instructions...
  • Page 3 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. 1152 - 001 - Introduction - 3...
  • Page 4 2 Safety 2.1 Safety definitions 2.5 Symbols on the product Warnings, cautions and notes are used to point out specially important parts of the manual. Stop. WARNING: Used if there is a risk of injury or death for the operator or bystanders if the WARNING! Be careful and use the instructions in the manual are not obeyed.
  • Page 5 Low speed needle. Air purge bulb. Use approved protective gloves. Use heavy-duty slip-resistant boots. Noise emissions to the environment according to European Directive 2000/14/EC and New South Wales legislation “Protection of the Environment Operations (Noise Control) Regulation 2017”. Noise emission data can be found on the machine label and in the Technical data chapter.
  • Page 6 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 7 1. Remove the throttle cable from the carburetor. Refer To disconnect and connect the throttle cable (543RS) on page 23 or To disconnect and connect the throttle cable (553RS) on page 23 . 2. Remove the 4 screws of the clutch cover (A) and disconnect the connectors (B).
  • Page 8 4 Servicing data 4.1 Servicing data (543RS) ▲ Lubricate with chain oil. 2.5 – 4 Nm 3 – 6 Nm 3 – 6 Nm 0.5 – 1 Nm 2.9 – 3.9 Nm 3 – 6 Nm 2 – 3 Nm 6 –...
  • Page 9 3 – 6 Nm 2.5 – 4 Nm 9 – 13 Nm 7 – 11 Nm 6 – 9 Nm 5 – 7 Nm 7 – 11 Nm 5 – 8 Nm 10 – 15 Nm 3 – 6 Nm 11 –...
  • Page 10 1.5 – 2.5 Nm 1.5 – 2.5 Nm 5 – 10 Nm 3 – 5 Nm 6 – 8 Nm 8 – 12 Nm 3 – 5 Nm 30 – 50 Nm 1.5 – 2 Nm 10 - Servicing data 1152 - 001 -...
  • Page 11 4.2 Servicing data (553RS) ▲ Lubricate with chain oil. (x2) 2.5 – 4 Nm (x2) 3 – 6 Nm (x2) 1 – 1.5 Nm (x4) 3 – 6 Nm (x4) 3 – 6 Nm (x4) 2 – 3 Nm 1.6 – 3 Nm 8 –...
  • Page 12 (x2) 3 – 6 Nm (x2) 2.5 – 4 Nm (x4) 6 – 9 Nm (x4) 1 – 1.5 Nm 3 – 6 Nm (x3) 4 – 6 Nm 10 – 20 Nm (x4) 1 – 1.5 Nm (x2) 3 – 6 Nm (x2) 11 –...
  • Page 13 1.5 – 2.5 Nm 1.5 – 2.5 Nm 5 – 10 Nm 3 – 5 Nm 6 – 8 Nm 8 – 12 Nm 3 – 5 Nm 30 – 50 Nm 1.5 – 2 Nm 1152 - 001 - Servicing data - 13...
  • Page 14 5 Servicing tools 5.1 Servicing tools 0. 3 14 - Servicing tools 1152 - 001 -...
  • Page 15 505 69 85-70 Air filter oil To lubricate the air filter. 531 00 60-76 Carburetor ad- To remove the needle caps and adjust the carburetor of 543RS. 530 03 55-60 justment tool 1152 - 001 - Servicing tools - 15...
  • Page 16 6 Repair instructions 6.1 Product overview for repair instructions (543RS) 1. Starter housing 6. Fuel tank 2. Muffler 7. Carburetor 3. Flywheel 8. Clutch cover 4. Ignition module 9. Cylinder cover 5. Clutch assembly 10. Air filter cover 16 - Repair instructions...
  • Page 17 11. Throttle handle 14. Clutch drum 12. Handle 15. Bumper 13. Bevel gear 6.2 Product overview for repair instructions (553RS) 1. Starter housing 9. Cylinder cover 2. Muffler 10. Air filter cover 3. Flywheel 11. Throttle handle 4. Ignition module 12.
  • Page 18 6.3 To clean and examine the product parts 6.4.2 To remove and install the stop switch 1. Use a flat screwdriver to loosen the stop switch. • Clean and examine all parts fully. You find more instructions in the chapter for each part if special tools or procedures are necessary.
  • Page 19 6.4.3 To disassemble and assemble the throttle handle 6.5.1 To remove and install the air filter cover Note: Make a note of how the components are installed (543RS) before you disassemble them. 1. Turn the knob (A) counterclockwise and remove the air filter cover (B).
  • Page 20 6.6 Starter 6.5.3 To remove and install the cylinder cover 1. Remove the 2 screws. 6.6.1 To remove and install the starter unit To remove and 1. Remove the cylinder cover. Refer to install the cylinder cover on page 20 . 2.
  • Page 21 3. Decrease the pressure of your thumb and let the 6.6.3 To assemble the starter unit starter pulley rotate clockwise slowly. This is to WARNING: Use protective glasses. The recoil decrease the tension of the recoil spring. spring can eject and cause injury. 1.
  • Page 22 6.7.1 To remove and install the air filter (543RS) To remove and 1. Remove the air filter cover. Refer to install the air filter cover (543RS) on page 19 . 2. Remove the air filter. 13. Make sure that you can turn the starter pulley ½ turn clockwise with the starter rope fully pulled out.
  • Page 23 2. Remove the 2 air filters. To remove and 1. Remove the air filter cover. Refer to install the air filter cover (543RS) on page 19 . 2. Loosen the nut (A) and remove the throttle cable guide (B) from the slot (C).
  • Page 24 6.8.3 To remove and install the carburetor (543RS) To remove and install 1. Remove the air filter. Refer to the air filter cover (543RS) on page 19 . 2. Close the choke valve and use compressed air to remove dirt around the carburetor.
  • Page 25 8. Disconnect the fuel hose (K) from the carburetor. Pump unit This is where the pump diaphragm (A) that supplies fuel 9. Install in the opposite sequence. to the metering unit from the fuel tank is found. The diaphragm is operated by pressure variations in the 6.8.5 Carburetor design engines crankcase through an impulse channel (B).
  • Page 26 6.8.6 Overview of the carburetor WTEA-7A (543RS) 26 - Repair instructions 1152 - 001 -...
  • Page 27 1. Screw 19. Snap ring 2. Fuel pump cover 20. Throttle shaft 3. Spring 21. Throttle valve plate 4. Idle speed screw 22. Screw 5. Fuel pump gasket 23. Return spring for throttle shaft 6. Fuel pump diaphragm 24. E-clip 7.
  • Page 28 6.8.7 Overview of the carburetor WT-1102 (553RS) 1. Screw 3. Rod 2. Air intake manifold 4. Air seals 28 - Repair instructions 1152 - 001 -...
  • Page 29 Replace worn or damaged parts. 9. Fuel pump diaphragm To remove and 1. Remove the carburetor. Refer to 10. Fuel screen install the carburetor (543RS) on page 24 . 11. Screws 2. Remove the screw (A). 12. Metering cover 13. Metering diaphragm 14.
  • Page 30 5. Remove the 4 screws (F). 10. To remove the jet needles, turn the needle counterclockwise while the tool is inserted and the limiter pushed. This will also release the limiter. 11. Remove the screw (O) and the throttle valve plate (P).
  • Page 31 14. Remove the screw (V) and the choke valve plate 6.8.9 To disassemble and assemble the carburetor (W). (553RS) Clean all parts and examine them for wear and damage. Replace worn or damaged parts. To remove and 1. Remove the carburetor. Refer to install the carburetor (553RS) on page 24 .
  • Page 32 6. Remove the 4 screws (I). 11. Remove the screw (R). AA BB 12. Remove the throttle lever (S), the return spring (T), the 2 bushings (U) and (V), and the seal (W). 13. Remove the screw (X) and the throttle valve plate (Y).
  • Page 33 Technical data on page 58 . adjustment, refer to test of the carburetor on page 36 . Basic factory adjustment 6.8.10 Carburetor adjustment (543RS) H = high speed needle 2¼ turns The carburetor has 3 adjustment controls: L = low speed needle 3¼...
  • Page 34 Note: At full throttle the rpm must be at 9500-10500 Note: The full throttle rpm with standard line length with standard length of nylon line. of 6.0 in. must be 10000 +/- 500 rpm. 2. Make sure that the engine speed is approximately 6.8.10.2 To do carburetor adjustment with unlocked 8500 rpm.
  • Page 35 6.8.11.1 To do carburetor adjustment with unlocked needle caps WT-1102 Note: Needle caps are installed on low speed needle and high speed needle to limit needle adjustment to ½ turn. This is to prevent incorrect adjustment. 1. Turn the needle caps counterclockwise to a full stop. 2.
  • Page 36 4. Lower the carburetor in a container with gasoline to find leaks. 5. Make sure that there are no leaks. 6.9 Muffler 6.9.1 To remove and install the muffler (543RS) To remove and 1. Remove the cylinder cover. Refer to install the cylinder cover on page 20 .
  • Page 37 6.10.1 To remove and install the spark plug To remove and install 1. Remove the muffler. Refer to the muffler (543RS) on page 36 . To remove and 1. Remove the cylinder cover. Refer to install the cylinder cover on page 20 .
  • Page 38 5. If no spark occurs, remove the spark plug and 5. Connect a multimeter between point (A) and point connect the ignition tester (A) to the spark plug cap (B) and measure the resistance. The measured Servicing tools on page 14 . (B).
  • Page 39 To do a spark test on page 10. Do a spark test. Refer to 6. Install in the opposite sequence. Make sure that the 37 . If there is no spark, the ignition module is To examine the ignition air gap is correct. Refer to module on page 38 .
  • Page 40 3. Remove the 4 screws (A) and move the clutch 8. Remove the clamp unit (F) and the 2 rubber housing cover (B) away from the clutch housing (C). bushings (G). 4. Remove the locking screw (D). 9. Remove the small snap ring in the clutch housing. 5.
  • Page 41 14. Assemble in the opposite sequence. Apply molybdenum grease on the splines (H) of the joint (I) and the power transmission axle (J) in the shaft. 11. Remove the snap ring in the clutch housing. 6.12 Flywheel 6.12.1 To remove and install the flywheel housing To remove and install 1.
  • Page 42 6. Install the piston stop in the spark plug hole. Refer to 6.13.2 To clean and examine the fuel filter Servicing tools on page 14 . 1. Remove the fuel tank cap. 2. Use the fuel filter hook to pull out the fuel hose (A) and the fuel filter (B) from the fuel tank.
  • Page 43 6.13.3 To remove and install the fuel tank (543RS) 6.13.4 To remove and install the fuel tank (553RS) 1. Drain the fuel tank. 1. Drain the fuel tank. 2. Remove the 4 screws (A) and the bumper (B). 2. Remove the 4 screws (A) and the bumper (B).
  • Page 44 6.14 Bevel gear 6.14.1 Overview of the bevel gear 1. Bevel gear housing 6.14.2 To remove and install the bevel gear 2. Grease plug 1. Remove the cutting attachment and the cutting 3. Ventilation screw attachment guard. 4. Clamp screw 2.
  • Page 45 6.14.3 To disassemble the bevel gear 5. Apply heat to the bevel gear housing until it is approximately 110 °C. Tap the bevel gear against a 1. Remove the bevel gear from the shaft. Refer to wooden block to remove the input axle assembly. remove and install the bevel gear on page 44 .
  • Page 46 6.14.4 To assemble the bevel gear 7. Put the input axle assembly into the bevel gear housing. 1. Clean all parts and replace worn or damaged parts if it is necessary. 2. Install the bearings on the input axle and the output axle.
  • Page 47 6.15 Engine To remove and 5. Remove the heat deflector. Refer to install the heat deflector (543RS) on page 37 . 6.15.1 To remove and install the heat insulator 6. Remove the 4 screws (A) and carefully remove the (543RS)
  • Page 48 8. Remove the 2 snap rings on the sides of the piston. 10. Remove the needle bearing and the 2 washers. Note: Make sure that the snap ring does not eject. 11. Remove the piston rings, if it is necessary. Keep you thumb on the snap ring.
  • Page 49 6.15.4 To clean the cylinder and piston CAUTION: Be careful when you clean the piston and cylinder. The soft aluminum parts are easily damaged. • Remove the carbon deposits from these parts: CAUTION: Make sure that the mark on the cylinder head gasket points at the flywheel side of the engine when you assemble the cylinder.
  • Page 50 • 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 51 8. Remove the front crankcase half (B), the crankcase 11. Clean and examine the crankshaft and the To clean and examine gasket (C), and the crankshaft assembly (D) from crankcase halves. Refer to the crankshaft and crankcase on page 51 . the rear crankcase half (E).
  • Page 52 6.15.9 To assemble the crankcase 5. Lubricate the crankshaft axle with oil and install the crankshaft assembly in the rear crankcase half. 1. Apply heat to the crankcase halves until they are approximately 110 °C. WARNING: Use protective gloves. 2. Use a hammer and a mandrel to install the bearings in the crankcase halves.
  • Page 53 To remove and 11. Install the cylinder cover. Refer to install the cylinder cover on page 20 . To remove and install 12. Install the starter unit. Refer to the starter unit on page 20 . To remove and install the 13.
  • Page 54 7 Troubleshooting 7.1 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 55 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 56 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 57 Increasing and decreasing speed Can not increase speed Defective heat insulation seal 1152 - 001 - Troubleshooting - 57...
  • Page 58 8 Technical data 8.1 Technical data 543RS 553RS Engine Cylinder displacement, cm 40.1 50.6 Cylinder diameter, Ø mm 40.5 45.5 Cylinder stroke length, mm 31.1 31.1 Idle speed, rpm 3000 2800 Recommended max. speed, rpm 12000 13000 Speed of output shaft, rpm...
  • Page 59 1152 - 001 - Technical data - 59...
  • Page 60 114 12 19-26 2020-09-28...

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