Husqvarna 540XP Mark III Workshop Manual
Husqvarna 540XP Mark III Workshop Manual

Husqvarna 540XP Mark III Workshop Manual

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Workshop manual
540XP Mark III
English
1719 - 002 - 19.04.2023

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Summary of Contents for Husqvarna 540XP Mark III

  • Page 1 Workshop manual 540XP Mark III English 1719 - 002 - 19.04.2023...
  • Page 2: Table Of Contents

    1.1 Document description..........3 7.1 Product overview..........12 1.2 Target group............3 7.2 To clean and examine the product parts....13 1.3 Revisions..............3 7.3 To connect the product to the Husqvarna 1.4 Safety..............3 Service Hub (HSH).............13 1.5 Servicing tools............3 7.4 Chain brake............13 7.5 Chain catcher............
  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1719 - 002 - 19.04.2023 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 European Directive 2000/14/EC, UK directives and regulations and New South Wales legislation "Protection of the Environment Operations (Noise Control) Regulation 2017". The guaranteed sound power level of the product is specified in Technical data on page 49 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 surfaces. After each operation. Clean the muffler, exhaust pipe and engine from dirt and unwanted lubricant. After each operation. Make sure that the saw chain does not move at idle speed.
  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ■ Lubricate with two-stroke oil. ● Lubricate with grease. ▲ Lubricate with chain oil. 3.0–4.0Nm 2x 3.0–4.0 Nm 4x 3.5–4.5 Nm 6x2.0–3.0 Nm 1.0–1.5 Nm 5.0–6.0 Nm 5.0–7.0 Nm 4x 1.5–2.5 Nm 13–15 Nm 13mm 1.0–1.5 Nm 3.0–4.0 Nm...
  • Page 8 2x 7.0–9.0 Nm 22.0– 25.0 Nm 12 mm 2x 6.0–8.0 Nm 2x 2.0–3.0 Nm 12.0–14.0 Nm 7x 7.0–9.0 Nm 16 mm 1.0–1.5 Nm 1.1–1.7 Nm 4x 7.0–9.0 Nm 2x 6.0–8.0 Nm 8 - Servicing data 1719 - 002 - 19.04.2023...
  • Page 9: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1719 - 002 - 19.04.2023 Servicing tools - 9...
  • Page 10 Item Description Article num- Piston stop To lock the crankshaft. 521 54 83-01 Fuel filter hook To pull out the fuel filter from the tank. 502 50 83-01 Mandrel To remove the flywheel. 502 51 94-01 HSH Interface Box Kit To do a check of the product and install updates to the firm- 598 07 28-02 ware.
  • Page 11: 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 12: Repair Instructions

    7 Repair instructions 7.1 Product overview 1. Air filter cover 15. Chain oil tank 2. Spark plug 16. Muffler 3. Spark plug cap 17. Chain brake and front hand guard 4. Air filter 18. Front handle 5. Vibration element 19. Right hand guard 6.
  • Page 13: To Clean And Examine The Product Parts

    7.3 To connect the product to the Husqvarna Service Hub (HSH) Note: It can be necessary to install firmware to a new spare part. Make sure that you know the Husqvarna Identification Number (HID) of the new spare parts before you connect the product to the Husqvarna Service Hub (HSH).
  • Page 14 7.4.2 To install the front handguard 7.4.3 To disassemble and assemble the chain brake 1. Push the lever and install the front handguard. WARNING: Make sure that the chain brake spring does not eject and cause injury. Use protective goggles. 1.
  • Page 15 4. Remove the 4 screws and the chain brake cover. 7. Remove the shain brake assembly. 5. Remove the chain brake spring. 7.4.4 To clean and examine the chain brake a) Hold one hand on the chain brake spring. Push a 1.
  • Page 16: Chain Catcher

    7.5.2 To replace the spiked bumper WARNING: The engine must be off. 1. Remove the clutch cover. 2. Remove the 2 screws, the chain catcher and the 2. Release the front handle. The guide bar tip falls onto spiked bumper. the stump.
  • Page 17: Muffler

    7.6 Muffler 4. Remove the screw and pull out the spark arrester screen. 7.6.1 To remove and install the muffler WARNING: Do not touch a hot muffler. Risk of burn injuries. 1. Remove the clutch cover. 5. Install in the opposite sequence. 7.6.2 To clean and examine the muffler 1.
  • Page 18 3. Install the opposite sequence. 4. Remove the throttle wire from the throttle trigger. CAUTION: Use a threadlocker when you install the 3 screws. 7.7.2 To disassemble and assemble the rear handle 1. Remove the screw and the handle cover. 5.
  • Page 19: Starter

    4. Remove the throttle wire from the tank unit. 3. Pull out the starter rope approximately 30 cm/12 in and put it in the notch on the pulley. 4. Let the pulley rotate slowly rearward to release the 5. Install in the opposite sequence. recoil spring.
  • Page 20 • Lubricate the starter pawls on the starter unit. 10. Push down the knot into position in the spring guide (B). • Lubricate the starter spring. 1 cm/0.5 in 7.8.3 To replace a broken or worn starter rope 1. Remove the starter rope from the starter unit. Refer To disassemble the starter unit on page 19 .
  • Page 21: Ignition System

    Only use spark spark plug. plugs recommended by Husqvarna, refer to the WARNING: To prevent the risk of fire, do operator's manual. not hold the spark plug near the spark plug hole.
  • Page 22 7.9.4 To remove the ignition module 11. Remove the 3 screws and the 2 covers for the ignition cable. 1. Remove the clutch cover. 2. Remove the starter unit (A). 3. Loosen the ignition cord (B) from the air conductor (C).
  • Page 23 7.9.5 To install the ignition module 3. Put a air gap gauge between the ignition module and the flywheel. Tighten the screw to the correct 1. Install the the ignition cable. Make sure that the Servicing tools on page 9 . torque.
  • Page 24: Flywheel

    11. Install the starter unit and the air conductor. Refer to 10. Remove the flywheel nut. To remove the flywheel on page 24 . 12. Install the clutch cover. 7.10 Flywheel 7.10.1 To remove the flywheel 1. Remove the starter unit (A). 11.
  • Page 25 7.10.2 To install the flywheel 6. Make sure that you install the springs in the correct position, as shown in the illustration. 1. Clean the crankshaft. 2. Put the flywheel on the crankshaft. Turn the flywheel until the key goes into the key slot on the shaft. 3.
  • Page 26: Centrifugal Clutch

    7.11 Centrifugal clutch 11. Install in the opposite sequence. 7.11.2 To clean and examine the centrifugal clutch 7.11.1 To remove and install the centrifugal clutch 1. Measure the diameter of the clutch shoes across the 1. Disengage the chain brake. full clutch hub.
  • Page 27: Lubrication System

    4. Lubricate the needle bearing with a grease gun. Use 5. Remove 4 screws, the chain guide plate (A), the engine oil or a bearing grease of high quality. muffler cover (B) and the cover for the pump housing (C). 6.
  • Page 28: Air Filter

    7.12.2 To disassemble and examine the lubrication b) Turn the adjustment screw counterclockwise to increase the chain oil flow. system To remove 1. Remove the lubrication system. Refer to and install the lubrication system on page 27 . 2. Remove the pin (A), the adjustment screw (B) and the spring (C).
  • Page 29: Husqvarna Connectivity Device

    Device. ® 7.14.1 To install the Husqvarna Connectivity Device ® Do the steps that follow to install the Husqvarna Connectivity Device. For more information about ® the Husqvarna Connectivity Device, refer to www.husqvarna.com. 1. Remove the screw and open the plastic cover.
  • Page 30 4. Remove the screw that hold the start/stop switch 8. Remove the connector from the holder. (A). 9. Remove the carburetor and the start/stop switch. 5. Remove the start/stop switch from the choke shaft (B). 6. Remove the 2 screws on the carburetor. 10.
  • Page 31 11. Disconnect the connectors on the carburetor. 3. Remove the 4 screws (A) and the 4 washers (B). 12. Remove the suction hose from the carburetor. 13. Install in the opposite sequence. 7.15.2 To disassemble the carburetor 4. Remove the metering cover (C) and the 2 gaskets To remove and 1.
  • Page 32 8. Remove the screw (R) and the throttle plate (S). 7.15.3 To clean and examine the carburetor 1. Clean all parts in clean gasoline. Use compressed air to dry the gasoline. Point the air through all channels in the carburetor housing and make sure that the channels are not blocked.
  • Page 33: Start/Stop Switch

    3. Connect the pressure tester to the fuel inlet on the 3. Remove the fuel hoses (A) from the air purge bulb. carburetor. Increase the pressure to 50kPa. Refer to Servicing tools on page 9 . 4. Remove the screw (B). 5.
  • Page 34 To remove and 3. Remove the front handle. Refer to 10. Remove the tank unit. install the front handle on page 17 . 4. Remove the air filter cover. 5. Remove the air filter. To remove and 6. Remove the carburetor. Refer to install the carburetor on page 29 .
  • Page 35 5. Install in the opposite sequence. 7.17.6 Air pressure in the fuel tank The two-way tank valve has a controlled opening pressure in the two directions. The controlled opening prevents positive pressure or vacuum in the fuel tank, and fuel leakage. Positive pressure, vacuum and fuel leakage decreases engine performance.
  • Page 36: Vibration Damping System

    7.18 Vibration damping system 7.19 Cylinder and piston 7.18.1 To disassemble and assemble the vibration 7.19.1 To remove the cylinder and piston damping system To disassemble 1. Remove the starter unit. Refer to the starter unit on page 19 . 1.
  • Page 37 8. Remove the 2 screws and the cover for the ignition 12. Remove the 2 screws. cable. 13. Remove the cylinder cover. 9. Remove the 2 screws and the ignition module. To remove and install 14. Remove the muffler. Refer to the muffler on page 17 .
  • Page 38 16. Put a cover on the crankcase opening. 7.19.2 To clean the cylinder and piston 1. Clean the piston crown. 17. Use pointed pliers to remove the snap ring (A). Keep your thumb on the snap ring to make sure that it 2.
  • Page 39 7.19.5 To examine the piston rings 1. Examine the piston rings for damage. 2. Replace damaged piston rings. 7.19.6 Piston damages Score marks on the piston Incorrect carburetor setting. Too high speed. Too low octane fuel. The fuel has a too low octane grade. Carbon build-up Incorrect carburetor setting.
  • Page 40 7.19.7 To install the cylinder and piston 8. Put a new cylinder base gasket on the crankcase. 1. Put a cover on the crankcase opening. 2. Lubricate the needle bearing (A) and put it into the connecting rod. Make sure the bearing moves freely in the connecting rod.
  • Page 41 13. Install the cylinder cover. 16. Install the cover for the ignition cable. 14. Install the 2 screws. 17. Install the spark plug. 18. Connect the spark plug cap to the spark plug. 19. Install the inlet pipe and make sure that the inlet plate (H) is in the correct position.
  • Page 42 Servicing 21. Push the inlet pipe through the carburetor bracket to 5. Attach the spark plug adapter (A). Refer to tools on page 9 . install the carburetor bracket. To remove and install 22. Install the tank unit. Refer to the tank unit on page 33 .
  • Page 43: Crankshaft And Crankcase

    10. Increase the pressure to 0.8 bar. Wait for 30 Note: Make sure that no dirt or object can come into seconds. Make sure the pressure does no decrease the bearings. to less than 0.6 bar. Remove the covers from the muffler and the carburetor, tighten the bolts to the 7.20.2 To disassemble the crankcase correct torque.
  • Page 44 6. Remove the 2 crankcase bearings. Refer to 3. Make sure that the bearing surfaces in the small Servicing tools on page 9 . end of the connecting rod are not worn or have discoloration. 4. Make sure that the crankpin bearing is attached correctly and does not have radial play.
  • Page 45: Guide Bar Bolts

    a) On the clutch side. 4. Attach the gasket (A) to one of the crankcase half on the clutch side. b) On the flywheel side. 5. Put a crankshaft cap (B) on the flywheel side of the Servicing tools on page 9 . crankshaft.
  • Page 46: To Repair A Damaged Thread

    5. Remove the guide bar bolt from the oil tank. 5. Put 2 spacers on the guide bar bolt. 6. Attach a nut to the guide bar bolt and tighten the 7.21.2 To install the guide bar bolt nut until the guide bar bolt is tightly attached to the crankcase.
  • Page 47: Troubleshooting

    8 Troubleshooting 8.1 Troubleshooting Symptom Possible causes Recommended step The product does not start. The air filter is dirty. Clean or replace the air filter. The choke is damaged or worn. Repair or replace the choke. Leakage or dirt in the fuel hose. Clean the or replace fuel hose.
  • Page 48 Symptom Possible causes Recommended step The engine rpm don not increase at The air filter is dirty. The air filter is dirty. full throttle. The tank valve is damaged. Replace the tank valve. Leakage or dirt in the fuel hose. Clean the or replace fuel hose.
  • Page 49: Technical Data

    9 Technical data 9.1 Technical data 540XP Mark III Engine Cylinder displacement, cm 39.1 Cylinder bore, Ø mm Stroke length, mm 31.1 Idle speed, rpm 3000 Maximum engine power acc. to ISO 7293, kW/hp @ rpm 1.9/2.6 @ 10500 Ignition system...
  • Page 50 50 - Technical data 1719 - 002 - 19.04.2023...
  • Page 51 1719 - 002 - 19.04.2023 Technical data - 51...
  • Page 52 1142918-26 2023-05-03...

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