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Workshop Manual
524L 525L LS LST LK
RJX RJD RS RX RXT RK
English

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Chapters

   Summary of Contents for Husqvarna 525L

  • Page 1

    Workshop Manual 524L 525L LS LST LK RJX RJD RS RX RXT RK English...

  • Page 3

    Service data ............15 Safety equipment ..........18 Repair instructions ..........24 Troubleshooting ............. 66 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English -...

  • Page 4: Table Of Contents

    Index Piston, dismantling ..........45 Piston, assembling ..........54 Air filter, dismantling and assembling ....32 Bevel gear ............61 Service data ............15 Bevel gear, dismantling........61 Special tools ............12 Bevel gear, assembling ........63 Starter recoil pulley, dismantling ......25 Starter recoil pulley, assembling ......

  • Page 5: Index

    Index English -...

  • Page 6: Introduction And Safety Instructions

    Introduction and safety instructions 2 Introduction and safety instructions Contents General ...........................7 Safety ..........................7 Target group ........................7 Modifications ........................7 Tools ..........................7 Structure .........................7 Numbering ........................7 General instructions ......................8 Special instructions ......................8 2.10 Symbols on the machine ....................9 2.11 Symbols in the Workshop Manual ..................9 - English...

  • Page 7: Introduction And Safety Instructions

    2.5 Tools Special tools are required for some stages. All service tools are listed in the Workshop Manual. Usage is made apparent in each section. Always use Husqvarna’s original: • Spare parts • Service tools • Accessories English -...

  • Page 8

    Introduction and safety instructions 2.8 General Instructions 2.9 Special Instructions The workshop where the machine is to be repaired The fuel used in the machine has the following must be equipped with safety equipment in accord- hazardous properties: ance with local regulations. • The fluid and its vapour are poisonous.

  • Page 9: Symbols In The Workshop Manual

    Introduction and safety instructions 2.10 Symbols on the machine 2.11 Symbols in the Workshop Manual The symbols below are embedded on the machine This symbol warns of personal injury Choke control when the instructions are not followed. Use protective gloves. Refuelling Use protective goggles.

  • Page 10: Technical Data

    3 Technical data Displacement Cylinder diameter Stroke length Max. output/speed cm3/cubic inch Ø mm/Ø inch mm/inch kW/rpm 525L: 25,4/ 1,55 34 / 1.34 28 / 1,10 0,9 / 8500 525LS 25,4/ 1,55 34 / 1.34 28 / 1,10 1,0 / 8500...

  • Page 11

    Technical data 3 Technical data Engage speed Spark plug Volume fuel tank Litre/US. pint 525L: 4000 (+/- 200) NGK BPMR8Y 0,51/1,08 525LS: 4000 (+/- 200) NGK BPMR8Y 0,51/1,08 525LST: 4000 (+/- 200) NGK BPMR8Y 0,51/1,08 525RJX: 4000 (+/- 200) NGK BPMR8Y...

  • Page 12: Special Tools

    Engine special tools 4 Engine special tools Contents Special tools ........................13 - English...

  • Page 13: Special Tools

    Engine special tools 4.1 Special tools Description Used for Order No. Torx wrench General disassembly / assembly tasks 578 28 90-01 Air gap tool (t 0.3mm) Adjust the air gap when installing the 514 22 10-01 ignition module Stopper (14 mm use) Fix piston in place when installing / 514 24 39-01 removing clutch, rotor and starter pulley.

  • Page 14

    Engine special tools For shaft (open) - English...

  • Page 15: Service Data

    Service data 5 Service data Note! Lubricate with two-stroke oil. Some of the screws are captive screws Lubricate with Grease and will remian into the cover. Apply thread lock: Three bond or loctite Tighten torque in Nm English -...

  • Page 16

    Service data - English...

  • Page 17

    Service data 15,0 English -...

  • Page 18: Safety Equipment

    safety equipment 6 Safety equipment Content Dismantling, muffler ......................19 Assembly, muffler ......................19 Dismantling, stop switch ....................19 Assembly, stop switch ....................19 Resistance, stop switch ....................20 Dismantling, throttle......................20 Assembly, throttle ......................22 - English...

  • Page 19: Muffler, Dismantling

    Safety equipment 6.1 Dismantling the muffler Remove the cover of the muffler. Dismantle the two screws to the muffler. Also remove the gasket. 6.2 Assembling the muffler Check the muffler, and if you find any deformation or cracks replace the muffler. If the muffler is fitted with a spark arrestor mesh, put it in place first.

  • Page 20: Stop Switch, Resistance Test

    Safety equipment 6.5 Resistance test - stop switch Dismantle the stop switch as outlined. Clean the contact areas. test the resistance by connecting a multimeter to the stop switch. The resistance should be as fol- low: ”0” pressed in - less than 0.1 Ω. ”1”...

  • Page 21

    Safety equipment Check that the throttle cable is fitted to the under- side of the pin on the throttle trigger lock. 6.6 Dismantling Throttle Remove screw that holding the handle bar, (A). Loosen the screws (B) holding the handle together. Note how the recoil spring (C) and the throttle lock (D) is mounted.

  • Page 22: Throttle, Assembling

    Safety equipment 6.7 Assembling the throttle Put all details in the left half of the handle. Make sure that the spring is correct fitted. Make sure that all cables is fitted in the handle and will not be clamped. Assemble the throttle trigger lock (A) and the anti vibration element (B).

  • Page 23

    Safety equipment English -...

  • Page 24

    Startapparat 7 Repair instructions Content Dismantling, recoil pulley....................25 Assembing, recoil pulley....................25 Replacing starter pawls ....................27 Checking the ignition spark ....................28 Dismantling, shaft and clutch housing from engine body ..........30 Assembing, shaft and clutch housing from engine body ..........30 Adjust the ignition module ....................31 Fuel system ........................32 Dismantling, air filter .......................32...

  • Page 25: Starter Recoil Pulley, Dismantling

    Repair instructions 7 Repair instructions 7.1 Dismantling the recoil pulley Remove the 3 screws and lift off the starter Remove the inner cover in the starter housing. Use a flat screw driver or similar tool. WARNING! Wear protective glasses. The return spring lies tensioned in the starter and can fly out and cause personal injury with careless handling..

  • Page 26

    Repair instructions Lubricate the spindle with a little grease and fit the starter pulley. Tighten the screw. Assemble a new starter cord. Slide it into the starter pulley’s slot as illustrated and then out through the cord guide in the starter housing. Make sure the knot on the end of the cord is as small as possible! NOTE!

  • Page 27: Start Pawls, Replacing

    Repair instructions 7.3 Replacing the starter pawls Fit the piston stop(A), no. 514 24 39-01 in the spark plug hole and loosen the starter pulley using special tool 581 96 55-01 (B). Remove the circlip holdings the starter pawls. Lift out the starter pawls and spring for replace- ment.

  • Page 28: Ignition Spark, Checking

    Repair instructions 7.4 Checking the ignition spark Dismantle the cylinder cover after the guard over the muffler and the air filter has been removed. Earth the spark plug on the cylinder and pull sharply on the start handle. A spark should be seen between the electrodes. If no spark is seen test with test spark plug no.

  • Page 29

    Repair instructions Fit the spark plug cap onto the ignition cable and make sure the ends of the wire is inserted into the centre of the spark plug cap for best contact. TIP! Lubricate the hole in the spark plug guard using for instance silicon spray to make it easier to push the ignition coil in.

  • Page 30: Dismantling, Shaft And Clutch Housing From Engine Body

    Repair instructions 7.5 Dismantling the shaft and clutch housing from engine body Remove the cylinder cover, guard over the muffler, and the air filter. Unhook the throttle cable from the carburettor and insulator. Disconnect the cables from ignition module. Remove the screws holding the clutch housing on the engine.

  • Page 31: Ignition Module, Adjusting

    Repair instructions 7.7 Adjust the air gap when installing the ignition module Adjust the air gap as needed to the correct value. • Loosen the bolts. • Position the gauge to adjust the gap and press the ignition module against the flywheel. • Tighten the bolts and check the air gap again. If the spark plug still does not fire, the ignition system should be replaced.

  • Page 32: Air Filter, Dismantling And Assembling

    Repair instructions 7.8 Fuel system In addition to the fuel tank and carburettor, the fuel system consists of the air filter, fuel filter and tank venting. All these components interact so that the engine receives the optimal mixture of fuel and air to make it as efficient as possible.

  • Page 33: Carburetor

    Repair instructions 7.11 Replacing the fuel filter The fuel hose in the tank contains a fuel filter. It is accessible through the fill hole. Pull out the filter with your fingers or with help of tool 502 50 83-01. If the filter is not too dirty, its surface can be cleaned with a brush.

  • Page 34

    Repair instructions The carburettor’s design The carburettor can be divided into three different functional units: the metering unit, the blending unit, and the pump unit The metering unit The needles (A) and the fuel control functions are located here. The needle valve (B) and control diaphragm (C) are vital to the carburettor’s function.

  • Page 35: Carburetor, Dismantling

    Repair instructions 7.14 Dismantling the carburettor Carefully remove the metering diaphragm (A) and gasket (B). Check the diaphragm for holes and wear on the pin (C). Replace the diaphragm if required. Connect pressure tester 531 03 06-23 to the fuel hose nipple.

  • Page 36

    Repair instructions Check the needle valve for damage on the tip (D) and in the lever arm groove. (E) Check the lever arm for damage to the groove (F) for the needle valve and wear on the mounting points towards the control diaphragm (G). Replace damaged components with new ones.

  • Page 37: Special Tools

    Repair instructions Unscrew the jet needles. Make sure they are clean and not damaged on the tip of the needle. NOTE! Note how the jets are positioned. (For example, the H-needle is a little shorter than the L-needle). Press out the main jet (A) with a suitable punch. Remove the plug (B).

  • Page 38: Carburetor, Assembling

    Repair instructions 7.15 Assembling the carburettor • Blow all channels in the carburettor compart- ment clean • Mount a new plug (A). Use a suitable punch to get a completely tight seal. • Press in a new main jet (B). • Mount the valves and springs. Tip! Any numbers on the valves should be able to be read from the outside. Make sure valves has a perfekt seal by locking at the edge of the valve with tha carburettor backlit, a light from the choke side.

  • Page 39

    Repair instructions Attach the various parts of the measuring unit in the reverse order as set out for dismantling. The lever arm height should be 0,66 mm +-0,16 mm under carburettor housing plane. Too high setting = too much fuel. Too low setting = too little fuel.

  • Page 40: Carburetor, Settings

    Repair instructions 5. Connect the throttle cable on the carburettor with the help of flat nose pliers. Check that the cable sits correctly in the guide on the clutch housing (A) and that it sits correctly in the cut-out (B) of the insulator. 6.

  • Page 41

    Repair instructions Basic setting With a trimmer head (Use Husqvarna T35 trimmer head with silent cord The carburettor is set to its basic setting when test ∅ 2.4 mm. The length of the trimmer cord will be run at the factory. The basic setting is “richer” than...

  • Page 42: Centrifugal Clutch, Dismantling

    Repair instructions 7.17 Dismantling the centrifugal clutch, flywheel and ignition module Remove the engine cover, clutch housing and spark plug. Screw the stopper (special tool A) into the plughole to fix the piston in place.Stopper 14 mm 514 24 39-01. Remove the two screws holding the ignition module and take away the earth cable.

  • Page 43

    Repair instructions Take out the flywheel nut (A). Rotor nut width across flats (WAF) M8 (WAF 12 NOTE! Slowly turn the rotor counterclockwise, and after applying the stopper (special tool) lightly to the piston head, loosen the nut. The piston head could be dama- ged if force is applied too sharply when loosening the nut.

  • Page 44: Centrifugal Clutch, Assembling

    Repair instructions 7.18 Assembling the flywheel, ignition module and centrifugal clutch When setting the key on the crankshaft, make sure the end face of the key is parallel with the crankshaft. Fix the piston in place with the stopper (special tool) and tighten the rotor nut.

  • Page 45: Cylinder And Piston, Dismantling

    Repair instructions Place the ignition module in position and fit the screws. Do not tighten the screws. Make sure the gap is: 0,3 mm Tighten the bolts while pressing the ignition module the flywheel. Assembly the sparkplug, all covers and the clutch covers with shaft.

  • Page 46

    Repair instructions Pull the cylinder straight up without turning it. There is a risk that a piston ring may break. Remove the piston pin circlips. Use small flat nose pliers and remove the piston pin circlips. TIP! Keep your thumb over the circlip to prevent it from flying out.

  • Page 47: Inspection

    Repair instructions 7.20 Cleaning, inspection After dismantling, clean the individual components: Scrape carbon deposits from the top of the piston. Scrape carbon deposits from the cylinder’s combustion chamber. Scrape carbon deposits from the cylinder’s exhaust port. NOTE! Scrape carefully off soot deposits using a not too sharp tool so as not to damage the soft aluminium parts.

  • Page 48

    Mixing ratio: 1:50 (2%). If Husqvarna two-stroke oil is not available another good quality two-stroke oil can be used. Mixing ratio: 1:33 (3%) or 1:25 (4%). - English...

  • Page 49

    Repair instructions Piston scoring caused by heavy carbon deposits Too heavy carbon depositing can cause damage similar to that caused by insufficient lubrication. However, the piston skirt has a darker colour caused by the hot combustion gases that are blown past the piston. This type of piston damage starts at the exhaust port where carbon deposits can become loose and get trapped between the piston and the cylinder...

  • Page 50

    Repair instructions Piston ring guide pin vibrated loose A too high engine speed can cause the ends of the piston ring to hammer against the guide pin when the piston ring moves in its groove. The intensive hammering can drive out the pin through the top of the piston causing serious damage also to the cylinder.

  • Page 51

    Repair instructions Foreign objects Everything other than clean air and pure fuel that enters the engine’s inlet port causes some type of abnormal wear or damage to the cylinder and piston. This type of increased wear shows on the piston’s inlet side starting at the lower edge of the piston skirt.

  • Page 52

    Repair instructions Larger, harder particles that enter the engine cause serious damage to the underside of the piston skirt. Cause: Action: Air filter damaged or Fit a new air filter. missing. Parts from the carbu- Regular service and rettor or intake system inspection.

  • Page 53

    Repair instructions Wear tolerances Cylinder bore When the surface coating is worn and aluminium appears Piston ring gap Max. 0,5 mm with the piston ring inserted in the lower part of the cylinder. Piston ring groove Max. 1,1 mm. Clean the groove before checking the measurement.

  • Page 54: Cylinder And Piston, Assembling

    Repair instructions 7.21 Assembling the piston and cylinder Clean the crankcase Fit the piston on the connecting rod so that the arrow on the piston points towards the exhaust port. Lubricate the piston pin’s needle bearing with a few drops of engine oil. NOTE! Place a rag in the crankcase opening to prevent the circlip from falling into the...

  • Page 55: Crankshaft, Dismantling

    Repair instructions 7.22 Dismantling crankshaft and crank- case The task of the crankshaft is to transform the reciprocating motion of the piston to rotation. This requires a stable design withstanding immense pressure and rotational and bending strain, as well as high rotational speed.

  • Page 56

    Repair instructions nspect the small end of the connecting rod. If seizure marks or discolouration are found in the bearing track the crankshaft must be replaced. Check the crank bearing. The connecting rod shall not have any radial play (up and down). It should, however, have axial play, in order to ensure good lubrication of the crank bearing among other things.

  • Page 57: Crankshaft, Assembling

    Repair instructions 7.23 Assembling the crankshaft and crankcase Check the crankshaft as set out in the section ”Inspecting the crankshaft”. Fit the new bearing in the crankcase using a press tool. During press fit of the bearing don’t push the inner bearing to fit Assemble the piston on the crankshaft.

  • Page 58: Clutch Drum

    Repair instructions 7.24 Replacing the clutch drum and drive shaft The centrifugal clutch has the task of transferring the power from the engine to the cutting equip- ment’s drive shaft. As the name implies, it works according to a centrifugal principle. This means the clutch’s friction shoes are thrown outwards towards the clutch drum at a certain engine speed.

  • Page 59

    Repair instructions Remove the screw (A) and screw (B) that hol- ding the clamp connection for the shaft. Remove the two screws holding the clutch hou- sing cover. Pull apart the shaft from the clutch housing. English -...

  • Page 60

    Repair instructions Remove the upper and lower clamp. Remove the anti vibrations element Note! replace the antivibration element if it is damaged orcracked. Remove the small circlip from around the shaft on the clutch drum using suitable circlip pliers. 515 41 95-01 Dismantle the clutch drum by using a specila tool, 581 44 10-01.

  • Page 61: Bevel Gear

    Repair instructions 7.26 Bevel gear The angle gear has two purposes: The first is to gear down the engine’s high speed to better suit the lower speed a saw blade or trimmer requires to work efficiently. Secondly, the angle gear contributes towards the operator’s working stance so that it is comfortable and at the same time efficient.

  • Page 62

    Repair instructions Remove the screw Heat the entire angle gear using a hot air gun to approx. 110°C. Knock the gear against a wooden block so that the input axle and the bearing fall out. Now lift out the output axle. Wear protective gloves.

  • Page 63: Bevel Gear, Assembling

    Repair instructions 7.28 Assembling the bevel gear Clean all component parts and replace if damaged or worn. Fit the bearings on respective axles. This is easier if the bearings are heated to approx. 110°C using a hot air gun. The bearings on the input axle are sealed on one side.

  • Page 64: Troubleshooting

    Troubleshooting 8 Troubleshooting Contents Engine does not start ....................67 Engine stops working during operation .................68 Engine is difficult to stop ....................68 Insufficient output or unstable rotation ................69 Other engine problems ....................70 - English...

  • Page 65: Engine Does Not Start

    Troubleshooting 8 Troubleshooting 8.1 Engine does not start Remove the spark plug from the cylinder, and holding the cylinder, pull the recoil starter and check whether any sparks appear between the spark plug electrodes. Symptom/Category Cause Action There are no sparks at the spark plug 1.

  • Page 66: Engine Is Difficult To Stop

    Troubleshooting 8.2 Engine stops working during operation Symptom/Category Cause Action There are no sparks at the spark plug 1. The switch has been touched, stopping Restart the engine 2. The switch is OFF Operate by setting to "RUN" or " I " 3.

  • Page 67: Insufficient Output Or Unstable Rotation

    Troubleshooting 8.4 Insufficient output or unstable rotation Symptom/Category Cause Action 1. Air has entered through the fuel pipe joint, Insert it securely etc. 2. Air has entered the fuel pipe due to a Replace crack or pin hole 3. Air has entered through the insulator pulse Insert it securely pipe insertion part, etc.

  • Page 68: Other Engine Problems

    Troubleshooting 8.5 Other Engine problems Symptom/Category Cause Action 1. The clutch spring is broken Replace the engine's clutch Even if the engine spring revolution is de- 2. The clutch is open due to rusting of the De-rust the clutch bolts, apply creased, the blade clutch bolts grease and re-assemble...

  • Page 70

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