Husqvarna 560 XP Mark II Workshop Manual
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Husqvarna 560 XP Mark II Workshop Manual

Husqvarna 560 XP Mark II Workshop Manual

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Workshop manual
560 XP Mark II, 560 XPG Mark II,
562 XP Mark II, 562 XPG Mark II
English
1993 - 003 - 18.08.2023

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Summary of Contents for Husqvarna 560 XP Mark II

  • Page 1 Workshop manual 560 XP Mark II, 560 XPG Mark II, 562 XP Mark II, 562 XPG Mark II English 1993 - 003 - 18.08.2023...

  • Page 2: Table Of Contents

    Contents 1 Introduction 7 Repair instructions 1.1 Document description..........3 7.1 Product overview for repair instructions....14 1.2 Target group............3 7.2 To clean and examine the product parts....16 1.3 Revisions..............3 7.3 Chain brake............16 1.4 Safety..............3 7.4 Chain catcher............20 1.5 Servicing tools............3 7.5 Muffler..............

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1993 - 003 - 18.08.2023 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions • Wear protective gloves when you replace the crankshaft bearings. The crankcase halves are hot, Warnings, cautions and notes are used to point out risk of burn injuries. specially important parts of the manual. • Make sure that the chain brake is engaged when you remove the pressure spring on the chain brake.

  • Page 5: Cutting Equipment Safety

    Noise emission to the environment label as per EU and UK directives and regulations, and New South Wales legislation "Protection of the Environment Operations (Noise Control) Regulation 2017". The guaranteed sound power level Technical of the product is specified in data on page 67 and on the label.

  • Page 6: 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 parts of the product and make sure that there is no oil on the After each operation. handles. Clean the muffler, exhaust pipe and engine from dirt and unwanted lubricant.

  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ■ Lubricate with two-stroke oil. ● Lubricate with grease. ▲ Lubricate with chain oil. 1.5 Nm 3–4 Nm 18–20 Nm 16 mm 1–2 Nm 16–18 Nm 10.5 Nm 16–18 Nm 5–6 Nm 22–25 Nm 13 mm 40 Nm 3–4 Nm...
  • Page 8 2–2.5 Nm 1.5–2.5 Nm 1 Nm 11–13 Nm 13 mm 9 Nm 3.5–4.5 Nm 2–3 Nm 3.5–4.5 Nm 6–7 Nm 6–7 Nm 6–8 Nm 4–5 Nm 5–6 Nm 1–2 Nm 2.5 Nm 7–9 Nm 8–10 7–9 Nm 3–4 Nm 3–4 Nm 3–4 Nm 8–9 Nm 8 - Servicing data...

  • Page 9: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1993 - 003 - 18.08.2023 Servicing tools - 9...
  • Page 10 Item Description Article num- Piston stop To lock the crankshaft. 575 29 36-01 Cover plate for exhaust To seal the exhaust port. 575 29 81-01 Cover plate for inlet To seal the intake system. 536 79 01-01 Plugs for inlet To seal the intake system.

  • Page 11: Diagnostic Tools

    Disconnect the servicing connector on the product. 5.2.1 Husqvarna Service Hub (HSH) The Husqvarna Service Hub (HSH) is used with a computer (not included) for Husqvarna products. The HSH Interface Box transmits data from the product to the Husqvarna Service Hub (HSH), for example product ID.
  • Page 12 CAUTION: Do not disconnect the HSH Interface Box until the update is completed. 12 - Servicing tools 1993 - 003 - 18.08.2023...

  • Page 13: Function Overview

    For best results and performance use Husqvarna two- stroke oil. If Husqvarna two-stroke oil is not available, use a two- stroke oil of good quality for aircooled engines. Speak to your servicing dealer to select the correct oil. 6.2.2.3 To mix gasoline and two-stroke oil...

  • Page 14: Repair Instructions

    7 Repair instructions 7.1 Product overview for repair instructions 14 - Repair instructions 1993 - 003 - 18.08.2023...
  • Page 15 1. Front handguard 10. Throttle trigger 2. Front handle 11. Fuel tank 3. Muffler 12. Carburetor 4. Cylinder cover 13. Cylinder and piston 5. Air filter 14. Lubrication system 6. Starter unit 15. Heated handle switch (XPG models only) 7. Start/stop switch 16.

  • Page 16: To Clean And Examine The Product Parts

    7.3 Chain brake 19. Clutch cover 20. Generator (XPG models only) 7.3.1 To disassemble the chain brake 21. Thermostat and heating element (XPG models only) 22. Ignition system WARNING: Use approved eye protection. The 23. Flywheel recoil spring can eject and cause injuries. 24.
  • Page 17 3. Carefully tighten the clutch housing in a vise. Use 6. Remove the screw (D), the chain tensioner cover the handguard to release the chain brake. (E), the adjustment screw (F), the shaft (G), the washer (H) and the O-ring (J). Remove the screw (K) and the chain guide (L).
  • Page 18 7.3.2 To assemble the chain brake 4. Lubricate the recess for the chain brake spring (Q) with grease. 1. Attach the knee joint to the brake band and tighten Servicing data on to the correct torque. Refer to page 7 . 2.
  • Page 19 6. Attach the cover (B) above the chain brake spring 7.3.3 To clean and examine the chain brake (C). Tighten the 3 screws (A) to the correct torque. 1. Carefully clean and examine all parts of the chain Servicing data on page 7 . Refer to brake.

  • Page 20: Chain Catcher

    7.4 Chain catcher 3. Remove the muffler (C), the gasket (D) and the heat deflector (E). Remove the screw (F) and pull out the spark arrester (G). 7.4.1 To replace the chain catcher WARNING: You must always replace a worn chain catcher.

  • Page 21: Handles

    7.6 Handles 7.6.2 To remove and install the heated front handle (XPG) 7.6.1 To remove and install the front handle (XP) 1. Remove the 2 screws and the cover for the heated front handle. 1. Loosen the screw in the vibration damping system. 2.
  • Page 22 5. Loosen the screw in the vibration damping system. 7.6.3 To disassemble and assemble the rear handle (XP) 1. Remove the screw and the handle cover. If the To remove and product has heated handles, refer to install the heated rear handle (XPG) on page 23 . 6.
  • Page 23 4. Remove the throttle wire and the throttle trigger. 7. Loosen the screw to the vibration damping system. 5. Assemble in the opposite sequence. 7.6.4 To remove and install the heated rear handle 8. Loosen the deflection limiter. (XPG) To remove 1.

  • Page 24: Starter

    9. Lift the saw carefully and pull down the hoses 10. Remove the screw and pull out the heated rear through and the throttle wire down through the handle and pull out the cables. carburetor bottom plate. Make sure that you understand how the cables are attached.
  • Page 25 b) Tighten the 4 screws to the correct torque. Refer 4. Remove the screw (D) and washer (E). Servicing data on page 7 . 7.7.2 To disassemble the starter unit WARNING: Use approved eye protection. The recoil spring can eject and cause injuries. To remove and 1.
  • Page 26 7.7.4 To assemble the starter unit 5. Install the starter pulley (C) in the starter housing with the washer (D) and the screw (E). WARNING: Use approved eye protection. The recoil spring can eject and cause injuries. 1. Install the spring cassette (A) and the 2 screws (B). Tighten the 2 screws to the correct torque.

  • Page 27: Ignition System

    CAUTION: Use resistor spark plugs to prevent problems during operation and permanent damage to the ignition system. Only use spark plugs recommended by Husqvarna, refer to the operator's manual. • Examine the spark plug if the engine is low on power, is not easy to start or does not operate correctly at idle speed.
  • Page 28 • If the spark plug is dirty, clean it and make sure that 3. Attach the ignition coil to the ignition cable and make Technical data the electrode gap is correct, refer to sure that the wire is folded along the cable. Move on page 67 .
  • Page 29 6. Pull out the spark plug cap through the hole in the 3. Put the spark plug cable through the hole in the crankcase. crankcase. 7. Remove the 2 screws and pull out the cable holder, cables and the ignition module from the crankcase. 4.

  • Page 30: Flywheel

    7. Install the air nozzle and the screw. 6. Remove the flywheel nut (A). 7. Remove the screws (B), starter pawls (C), springs (D) and washers (E). 8. Install the spark plug cap to the spark plug. 8. Put the flywheel puller tool (F) in the center of the 9.

  • Page 31: Centrifugal Clutch

    7.9.2 To install the flywheel 6. Put the air gap gauge between the flywheel and the Servicing tools on page 9 . ignition module. Refer to 1. Clean the crankshaft. 2. Put the flywheel on the crankshaft. Turn the flywheel until the key goes into the key slot on the crankshaft.
  • Page 32 5. Remove the spark plug and put a piston stop in the 9. Carefully remove the clutch shoe springs from the spark plug hole. side that does not have text. 10. Assemble the centrifugal clutch in the opposite sequence. Clean the bearing and apply new grease on it.

  • Page 33: Lubrication System

    To disassemble and 7.10.2 To clean and examine the centrifugal clutch 3. Remove the clutch. Refer to assemble the centrifugal clutch on page 31 . 1. Clean and examine the clutch shoe springs (A), the clutch hub (B) and the clutch shoes (C) carefully. 4.

  • Page 34: Air Filter

    6. Use chain oil to lubricate all moving parts. The pump unit (A) moves the fuel from the fuel tank to the metering unit in the carburetor. One side of the 7. Assemble the lubrication system in the opposite pump diaphragm is connected to the crankcase and sequence.
  • Page 35 • Part throttle mode In the full throttle mode both valves are open and fuel is supplied through all four diffuser jets (D, E, F and G). • Full throttle mode The air throttle valve (J) is fully open. In cold start mode the choke valve (H) is completely shut.
  • Page 36 6. Disconnect the air filter holder from the rubber parts 9. Remove the cable connector (C) from the on the sides. connection clamp (D). 7. Remove the air filter holder. Note: Make a note of the position of the return hose and the wires on the air filter holder.
  • Page 37 13. For XPG models, disconnect the thermostat wires 15. Remove the carburetor. and the generator wires and remove the heating elements. 16. Disconnect the cable connectors. 14. Push down the lever to release the carburetor. 17. Install in the opposite sequence. 1993 - 003 - 18.08.2023 Repair instructions - 37...
  • Page 38 7.13.4 Carburetor components 38 - Repair instructions 1993 - 003 - 18.08.2023...
  • Page 39 3. Examine all parts for damage and wear. Replace the find leaks. parts that show sign of damage. 5. Make sure that there are no leaks. 4. Use Husqvarna Service Hub (HSH) to examine ™ Adjustment of the the AutoTune unit.

  • Page 40: Start/Stop Switch

    35 . carburetor must be approved on the test “Product tests” in Husqvarna Service Hub (HSH) before use. Refer to 4. Remove the rubber seal (A) from the start/stop Husqvarna Service Hub (HSH) for instructions.

  • Page 41: Fuel Tank

    7.14.2 To do a function test of the start/stop switch 7. Remove the screw and the chain catcher. 1. Clean the surfaces where you will measure the resistance. 2. Connect a multimeter to the blue cable and the cylinder to measure the resistance. The resistance must not be more than 0.5 Ω.
  • Page 42 12. Remove the tank unit. 7.15.2 To replace the fuel filter 1. Remove the fuel tank cap. 2. Use a fuel filter hook to pull out the fuel hose and the Servicing tools on page 9 fuel filter. Refer to CAUTION: Be careful not to cause damage to the hoses when you remove the tank unit.
  • Page 43 3. Use a fuel filter hook to pull out the fuel hose and the 6. Attach the new fuel hose to the fuel tank as the Servicing tools on page 9 . fuel filter. Refer to illustration shows. 7. Attach the fuel filter to the new fuel hose. 8.

  • Page 44: Vibration Damping System

    7.16 Vibration damping system 4. Install a new air purge bulb in the opposite sequence. 7.16.1 To disassemble and assemble the vibration 7.15.6 Air pressure in the fuel tank damping system The two-way tank valve has a controlled opening 1. Use a Torx screwdriver to remove the vibration pressure in the two directions.

  • Page 45: Generator

    7.17 Generator 6. Remove the 2 screws and pull out the generator and the wire. 7.17.1 To remove and install the generator To remove and 1. Remove the fuel tank. Refer to install the fuel tank on page 41 . To remove and 2.
  • Page 46 3. Remove the 2 screws and the insulation wall. 6. Remove the 4 screws and lift the cylinder. 4. Remove the carburetor. 5. Remove the muffler and the heat deflector. CAUTION: Make sure that the piston does not move. The guide pin can cause damage to the piston if it falls.
  • Page 47 9. Use pliers to remove the snap ring (A) from the pin. 7.18.2 To clean the cylinder and piston Keep your thumb adjacent to the snap ring to make 1. Clean the piston crown. sure that the snap ring does not eject. Discard the 2.
  • Page 48 3. Examine the parts for damage. Replace damaged 3. Lubricate the needle bearing (A) and put it into the parts. connecting rod. Make sure the bearing moves freely in the connecting rod. 7.18.5 To examine the piston 1. Make sure that the needle bearing is not damaged. 2.
  • Page 49 8. Put a new cylinder base gasket (E) on the Note: When you operate the product, the torque of crankcase. the screws decreases. 13. Install the remaining parts in the opposite sequence to how they were removed. 7.18.7 To do a pressure test of the cylinder 1.

  • Page 50: Crankshaft And Crankcase

    7.19 Crankshaft and crankcase 7. Remove the muffler and attach the outlet cover. Servicing tools on page 9 for the correct Refer to cover. Tighten the screws for the muffler. 7.19.1 To get access to the crankshaft and crankcase 1. Drain the oil tank and the fuel tank. 2.
  • Page 51 7.19.2 To disassemble the crankshaft and the 6. Remove the crankcase half on the flywheel side from the crankshaft. Use the crankcase disassembly crankcase Servicing tools on page 9 . tool. Refer to 1. Get access to the crankshaft and crankcase. Refer To get access to the crankshaft and crankcase on page 50 .
  • Page 52 8. If the crankcase bearing is attached to the 3. Use a screwdriver to remove the seal ring. crankshaft, use a puller tool to remove the crankcase bearing. 7.19.3 To replace the seal rings 4. Attach the guide ring (A) on the crankshaft axle. Note: Hold the outer part of the bearing when you replace the seal ring.
  • Page 53 7. Use the press tool to push the new seal ring to the 3. Make sure that the bearing surfaces in the small Servicing tools on page 9 correct position. Refer to end of the connecting rod are not worn or have discoloration.
  • Page 54 5. Push a T-handle Torx T27 or an equivalent tool c) Attach the bearing with the sleeve, the screw through the air channel to remove dirt. Compressed and the nut. air can also be used to clean the air channel. Note: The vise, the screw and the nut are not necessary when you use a press.
  • Page 55 3. Use the rear side of the sleeve and pull the 5. Attach the gasket (C) between the crankcase crankshaft into the crankcase half on the clutch side. halves. Pull until the crankshaft shoulder touches the main Servicing 6. Use the crankshaft assembly tool, refer to bearing.

  • Page 56: Guide Bar Bolts

    7. Install the 6 screws (D) and tighten them in turn to 3. Remove the guide bar and the saw chain. Servicing data on page the correct torque. Refer to 4. Hit the guide bar bolts until they fall into the oil tank. 5.

  • Page 57: Thermostat And Heating Element

    3. Pull the steel wire to pull out the guide bar bolt. 6. Remove the 2 screws and the cover for the heated front handle. 4. Make sure that the square head of the guide bar bolt is correctly attached in the oil tank. 5.

  • Page 58: To Repair A Damaged Thread

    10. Pull out the wires from the handle. Be careful when 13. Disconnect the thermostat wire and remove the you pull the wire through the handle. thermostat. 14. Disconnect the ground cable and remove the heating element from the carburetor. 15.
  • Page 59 3. Attach the thread insert with an applicable screw and wrench. 1993 - 003 - 18.08.2023 Repair instructions - 59...

  • Page 60: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting 8.3 To do troubleshooting of the heating element in the rear handle You can do the troubleshooting procedure with most components attached to the product. The necessary 1. Disconnect the cable connections (A) and (B). tools for the troubleshooting procedure is: •...

  • Page 61: To Do Troubleshooting Of The Generator

    8.4 To do troubleshooting of the generator 8.5 To do troubleshooting of the start/stop switch 1. Measure the resistance in the generator between point (A) and (B). The resistance for the generator 1. Disconnect one of the wires from the start/stop must be 0.5 Ω.

  • Page 62: To Do Troubleshooting Of The Heating Element And The Thermostat

    8.6 To do troubleshooting of the heating 3. Measure the resistance at an air temperature of 15 °C or more. The resistance must be 0.0 Ω when element and the thermostat the air temperature is 15 °C or more. Replace the 1.

  • Page 63: Troubleshooting Diagram

    8.7 Troubleshooting diagram Starter rope Perform “Cleaning and inspec- Damaged starter Change part or entire tion” of starter housing does not retract housing starter if needed. (see separate instr.) Sticking starter Change part or entire Damaged starter housing housing starter if needed. Check air gap between Start rope stuck Change part if needed.

  • Page 64: Engine Running Issue

    Does the Crankcase gaskets engine Crankcase start ? Issue still remains? Perform a visual inspection of interface between Contact your Husqvarna carburetor and intake rubber for leakage. Local Sales Company for advice. 64 - Troubleshooting 1993 - 003 - 18.08.2023...

  • Page 65: Engine Running Issue

    Check cables and connectors for wear. Product OK Check torque on ignition coil screws. Check the ground wire. Issue still remains? Contact your Husqvarna Local Sales Company for advice Leakage Check function of decompression valve (if equipped). Check mounting/interface intake rubber and carburetor.

  • Page 66: Ignition System Diagnostic Flow Chart

    8.10 Ignition System Diagnostic Flow Chart Perform visual inspection of unit. Inspect spark plug wire, boot connections. Repair/replace any problem items Install new, properly gapped, manufacturer specified spark plug. Stop switch must be in run position. Perform Spark Test (See separate instructions). End Test Is a strong Does engine...

  • Page 67: Technical Data

    9 Technical data 9.1 Technical data Husqvarna 560XP Husqvarna 560XPG Husqvarna 562XP Husqvarna 562XPG Mark II Mark II Mark II Mark II Engine Cylinder displace- 59.8 59.8 59.8 59.8 ment, cm Idle speed, rpm 2800 2800 2800 2800 Maximum engine power acc.
  • Page 68 Husqvarna 560XP Husqvarna 560XPG Husqvarna 562XP Husqvarna 562XPG Mark II Mark II Mark II Mark II Type of drive sprock- Rim/7 Rim/7 Rim/7 Rim/7 et/number of teeth Saw chain speed at 24.6 (0.325) 24.6 (0.325) 133% of maximum 28.4 28.4 engine speed, m/s 28.4 (3/8)
  • Page 69 1993 - 003 - 18.08.2023 Technical data - 69...
  • Page 70 70 - Technical data 1993 - 003 - 18.08.2023...
  • Page 71 1993 - 003 - 18.08.2023 Technical data - 71...
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This manual is also suitable for:

560 xpg mark ii562 xp mark ii562 xpg mark ii

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