Husqvarna 226R Workshop Manual Download Page 44

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502 50 70-01

502 50 18-01

Cylinder and piston

Assembly

Lubricate the gudgeon pin’s needle bea-
ring with a few drops of engine oil.

Assembly

Lubricate the gudgeon pin’s needle bea-
ring with a few drops of engine oil.

Direct the arrow on the top of the piston
towards the exhaust port. Press in the
gudgeon pin and fi t the circlips.

NOTE!

Place a rag in the crankcase opening to prevent the circlip from falling into the
crankcase in case it should fl y out.

Do not forget the spacer washers on each side of the piston bolt bearing.

Check that the circlips are properly seated in the grooves.

Check that the pulse channel in the cylin-
der is open.

Assemble the cylinder with the help of as-
sembly set 502 50 70-01.

Check that the pulse channel in the cylin-
der is open.

Place a new cylinder base gasket on the
crankcase. Lubricate the piston and the
big-end bearing with a few drops of engine
oil.

Assemble the cylinder with the help of the
piston ring compressor in the assembly

NOTE!

Do not turn the cylinder, as the
piston rings can easily be broken.

Tighten the 2 screws diagonally
crosswise.

Inspect the distance piece for crack forma-
tion or other damage that may result in
leakage, which in turn can cause uneven
idling and starting diffi

culties.

Check that the impulse channel (A) is
open.

Assemble the remaining parts in the re-
verse order as set out for dismantling. See
respective sections in the manual.

set 502 50 70-01.

Summary of Contents for 226R

Page 1: ...1 German Workshop manual English 226R RJ RS ...

Page 2: ..._______________7 3 Fuel system ___________________________________ 13 4 Centrifugal clutch ______________________________ 25 5 Angle gear____________________________________ 31 6 Cylinder and piston_____________________________ 35 7 Crankshaft and crankcase________________________ 45 8 Tools_________________________________________ 51 9 Technical Data_________________________________ 55 Husqvarna ...

Page 3: ...l The assembly of other equipment or accessories or spare parts not approved by Husqvarna can result in the failure to meet these safety demands and that the person carrying out assembly bears responsibility for this Fire risk Handle fuel with respect as it is extremely inflammable Do not smoke and ensure there are no open flames or sparks in the vicinity Make sure there is a working fire extingui...

Page 4: ...Starter 1 5 1 Starter Contents Dismantling _______________________________________ 4 Assembly__________________________________________ 5 Replacing the drive _________________________________ 6 ...

Page 5: ...rew A in the centre of the starter pulley Carefully lift away the starter pulley B WARNING Be careful not to injure your thumb when the starter pulley rotates in reverse Dismantling Remove the 5 bolts and lift off the starter Dismantling Remove the 5 bolts and lift off the starter Loosen the spring tension Lift up the starter cord on the starter pulley and allow it to rotate backwards until the sp...

Page 6: ...and position the starter pulley Lubricate the return spring and the starter pulley s stub axle with cold resis tant grease or thin oil Move the starter cord through the guide in the starter housing A Guide the free end of the return spring B in towards the cut out in the hub of the starter pulley and slide the starter pulley down into the starter housing Fit the screw C Fit the starter handle Fit ...

Page 7: ...f it is worn or defective Clamp the blades of the drive dog togeth er with a pair of pliers and push it out from the drive disc cup Tighten the return spring Pull out the starter cord completely and slow the starter pulley with your thumb Lift the starter cord up out of the cut out on starter pulley Then turn the starter pulley anti clock wise 5 revolutions Check the spring tension With the cord c...

Page 8: ...2 7 2 Electrical system Electrical system Contents Checking the ignition spark_______________________ 8 Dismantling __________________________________ 10 Assembly_____________________________________ 11 ...

Page 9: ...e 0 6 mm Adjust the gap as needed to the correct value with the side electrode If the electrodes are worn more than 50 the spark plug should be changed If the electrodes are worn more than 50 the spark plug should be changed Too large a spark gap entails a great deal of stress on the ignition module and risk for short circuiting Also check that the stop switch is in the start position Dismantle th...

Page 10: ... the ignition cable is not damaged Remove a segment of cable if required to get sufficient contact at the connection coil Use pliers no 502 50 06 01 to make a new hole in the ignition lead once a piece of the damaged lead has been cut off When a part of the ignition lead has been cut off it helps to use pliers no 502 50 06 01 to make a new hole in the ignition lead to fit the contact coil Attach t...

Page 11: ...ule Pull out the cable shoe C Remove the screws D and remove the ignition module Disconnect the short circuit cables A Remove the 4 screws A and lift off the engine body Disconnect the short circuit cables A Separate the engine body from the fan housing cover NOTE Do not loose the insulation sleeves that are placed between the ignition module and the cylinder Still no spark Check other cables and ...

Page 12: ...otation are visible from the outside Remove the nut holding the flywheel Dismantle the centrifugal clutch Position the piston stop 522 43 18 01 in the spark plug hole so that it is on top of the piston top in the combustion room Remove both screws E that hold the centrifugal clutch Lift off the clutch Note the spacers between the flywheel and the centrifugal clutch Remove the flywheel Assembly Che...

Page 13: ... ignition module on the cylinder NOTE Do not forget the spacer sleeves between the cylinder and the ignition module Adjust the air gap between the ignition module and the permanent magnets on the flywheel to 0 3 mm and tighten the screws Assemble other parts in the reverse order as set out for dismantling ...

Page 14: ...________________ 15 Fuel filter_____________________________________ 15 Carburettor___________________________________ 16 Assembly ____________________________________ 20 Carburettor settings____________________________ 20 Throttle handle _______________________________ 21 Trouble Shooting Guide ________________________ 23 ...

Page 15: ...ree of cleaning agent before it is impregnated with air filter oil Air filter Dismantle the air filter cover by turning the knob Lift off the air filter The filter is manufactured of foamed plastic and should be cleaned in tepid soapy water A damaged filter should be replaced with a new filter Air filter Dismantle the air filter cowling Remove the air filter and clean it in warm soapy water A dama...

Page 16: ...nd the hole in the fuel cap E clean with compressed air Assemble the fuel cap in reverse order to that in which it was dismantled Make sure the seal F is not damaged Fuel filter The fuel hose in the tank contains a fuel filter It is accessible through the fill hole Pull out the filter using tool 502 50 83 01 If the filter is not too dirty its surface can be cleaned with a brush Otherwise it must b...

Page 17: ...round the carburettor 3 Disconnect the throttle cable 4 Dismantle the fuel hoses from the carburettor and note how they are con nected so that the fuel pump works as intended 5 Open the choke valve and remove the carburettor screws Lift off the air filter holder Carburettor Dismantling Remove the carburettor cover and the air filter then blow clean around the carburet tor Dismantle the throttle ca...

Page 18: ...act Clean the valve housing Carefully lift up non return valve C using your nails Clean the valve housing and check that the channels are open Check that the non return valve s seals D are undamaged by carefully squeezing the short sides together Replace the valve if necessary Remove the pump diaphragm to check for wear and damage Clean or replace the fuel screen 1 Carefully remove the pump diaphr...

Page 19: ...k wear to the tip of the needle valve and the groove for the lever arm Replace damaged parts with new parts Replace the needle valve s seat Press out the needle valve s seat for replacement Use a suitable punch Ø 4 5 mm NOTE Replace the seat needle valve and lever arm at the same time The needle valve s seat should be pressed in level with the carburettor housing Use a vice with soft jaw guards to...

Page 20: ... the carburettor Clean and inspect all parts Worn or damaged parts are replaced with new ones Pay attention to the following when the carburettor is assembled in the reverse order to dismantling 1 Make sure the sealing ring A has its wide edge against the carburettor housing 2 The screen B must be clean and undamaged Check that the carburettor is sealed Connect the pressure tester no 531 03 06 23 ...

Page 21: ... speed jet 1 Screw the high speed jet H into the bottom of its seat 2 Then screw out the needle 1 5 turn basic setting 3 Run the engine warm for about 4 minutes at 9 500 10 000 r min 4 If the idle speed exceeds 3 700 r min it can be lowered with the idle screw T 5 Then turn the H needle anticlockwise so that the speed drops by 300 r min 6 Then adjust the idle speed to 2 800 3 100 r min by turning ...

Page 22: ...moved from the handle only screw A needs to be re moved If the two halves of the throttle are to be separated all screws must be removed Using a screwdriver carefully lift up the lock preventing accidental throttle op eration and slow down rotation until the spring tension ceases Lift off the lock Note the location of the return spring Lift up the throttle control C and note how the return spring ...

Page 23: ... down 4 Seat the return spring H in position 5 Position the lock preventing accidental throttle operation over the bearing pin and tension the spring until the lock can be slid down to engage and hold the throttle control 6 Check that the throttle cable and short circuit cables are properly seated and will not get pinched 7 Check that the spring B is in position in the right hand handle half Place...

Page 24: ...alve s lever Lever arm damaged Lever arm too high Lever arm too low Lever arm does not work correctly Needle valve s spring The spring is deformed The spring is not fitted correctly Control diaphragm Diaphragm is damaged Faulty seal Needle valve Valve jams Valve worn Foreign object in the valve guide iffi cult to start Flooding fuel leakage Diffi cult to prime when starting Engine does not idle Id...

Page 25: ...3 24 Fuel system ...

Page 26: ... Centrifugal clutch Centrifugal clutch Contents Centrifugal clutch dismantling ___________________ 26 Centrifugal clutch assembling ___________________ 27 Clutch drum drive axle and AV element____________ 27 ...

Page 27: ...ine can idle without the cutting equipment s drive shaft rotating Centrifugal clutch Dismantling Dismantle the cylinder cover and the air filter cover Separate the short circuit cables and disconnect the throttle cable Remove the screws holding the clutch cover and lift off the assembly Centrifugal clutch Dismantling 1 Remove the cover over the air filter 2 Separate the short circuit cables 3 Disc...

Page 28: ...lamping half down wards so that its guide pin comes off of the AV element Twist apart the clutch Inspect and replace damaged or worn parts Twist apart the clutch and inspect the spring and lining with regard to wear and damage The thickness of the lining must be at least 1 0 mm at the most worn point NOTE Both clutch shoes should be replaced even if only one of them is showing signs of heavy wear ...

Page 29: ...e the dismantling Push the clutch drum out of the cover Push out the clutch drum The pass between the ball bearing and the clutch drum shaft might be stiff If that is the case then warm the entire cover up using a hot air gun WARNING Make sure the centre pins A are placed on each side of the counterhold B Otherwise there is a risk of the clutch cover being damaged Dismantle the circlip and heat th...

Page 30: ...V element E in with talc to facilitate the assembly and extend its service life 3 Push the AV element into the clutch cover 4 Push the lower bracket F into the AV element and then the upper bracket G 5 Assemble the complete clutch cover on the shaft and make sure the centre screw H can be screwed into the hole in the shaft Check the inside diameter of the clutch drum If it exceeds 54 5 mm it shoul...

Page 31: ...4 30 Centrifugal clutch ...

Page 32: ...5 31 5 Angle gear Angle gear Contents Dismantling __________________________________ 32 Assembly ____________________________________ 33 ...

Page 33: ...Remove the support washers and the dust protection washer 5 Use a pair of circlip pliers to remove the circlips holding the ball bearings by the output shaft see picture and the input shaft respectively Dismantling 1 Remove the cutting equipment and guard 2 Remove the screw A and lift off the plate B 3 Loosen the screw C holding the bevel gear against the shaft and remove the bevel gear Dismantlin...

Page 34: ...ng Clean all components and inspect them for wear and damage Replace damaged com ponents NOTE Both cogwheels should be replaced at the same time even if only one of them is damaged Grease the cogwheel thoroughly 3 Grease the whole cogwheel with a large amount of gear housing grease 503 97 64 01 as per the picture Warm the gear housing to about 140 C and push the output shaft into the gear housing ...

Page 35: ...t tom in their positions 2 Make sure the gear housing is still hot enough about 140 C after the output shaft has been fitted 3 Lift the input shaft in place using a suit able pair of pliers or a suitable sleeve 4 Make sure the ball bearings touch bot tom in their positions 5 Fit the circlip for the ball bearings on the input shaft 6 Assemble cutting attachment and spray guards in the reverse order...

Page 36: ...___________________ 38 Cleaning inspection______________________________ 39 Analysis and actions______________________________ 39 Service tips _____________________________________ 44 Wear tolerances _________________________________ 44 Assembly_______________________________________ 45 ...

Page 37: ...e the piston Push the gudgeon pin from the piston using punch 505 38 17 05 If the pin is too tight dismantling is facili tated by carefully heating the piston using a hot air gun NOTE Do not lose the spacers that are on each side of the little end The cylinder and the piston are two of the components exposed to most strain in the engine They must withstand for example high speeds large temperature...

Page 38: ...or are discoloured caused by overheating they must be replaced NOTE Scrape carefully with not too sharp a tool so as not to damage the soft aluminium parts Cause Incorrect carburettor setting Recom mended max speed exceeded Incorrect oil mixture in the fuel Too low octane fuel Action Insufficient lubrication The piston has small to medium size score marks usually in front of the exhaust port In ex...

Page 39: ...oove and has therefore not been able to seal against the cylinder wall which has resulted in further intensive tem perature increases in the piston Seizure scores along the entire piston skirt on the inlet and exhaust sides Action Cause Wrong type of two stroke oil or petrol Incorrect oil mixture in the petrol Incorrect carburettor setting Piston scoring caused by heavy carbon deposits Too heavy c...

Page 40: ...es on the piston s inlet side caused by a broken roller retainer Deep irregular grooves caused by a loose circlip Shown here on the piston s inlet side 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 ...

Page 41: ...wear shows on the piston s inlet side starting at the lower edge of the piston skirt The damage is caused by badly filtered air that passes through the carburettor and into the engine Cause Faulty air filter Small dust particles pass through the filter The filter is worn out due to too much cleaning whereby small holes have appeared in the material Unsuitable filter maintenance such as wrong metho...

Page 42: ...ticles that enter the engine cause serious damage to the underside of the piston skirt Cause Air filter damaged or missing Parts from the carburettor or intake system have come loose and entered the engine Action Fit the air filter correctly Fit a new air filter Fit a new air filter Regular service and inspection Larger softer particles that penetrate into the engine cause damage to the piston ski...

Page 43: ...d or if carbon deposits remain the compression pressure can leak through Check the wear on the piston ring by placing it in the lower part of the cylinder bore Position a suitable punch on the bolt head and give a few sharp knocks with a hammer If the bolt still does not loosen repeat the procedure Wear tolerances Defect Broken cooling fins damaged threads or sheared bolts by the exhaust port Seiz...

Page 44: ...lse channel in the cylin der is open Assemble the cylinder with the help of as sembly set 502 50 70 01 Check that the pulse channel in the cylin der is open Place a new cylinder base gasket on the crankcase Lubricate the piston and the big end bearing with a few drops of engine oil Assemble the cylinder with the help of the piston ring compressor in the assembly NOTE Do not turn the cylinder as th...

Page 45: ...6 44 Cylinder and piston ...

Page 46: ...kshaft and crankcase Crankshaft and crankcase Contents Dismantling ____________________________________ 48 Inspecting the crankshaft _________________________ 49 Assembly ______________________________________ 50 ...

Page 47: ...pump for the fuel air mixture when this is sucked from the carburettor and is forced into the cylinder s combustion chamber The crankcase must be perfectly sealed so as not to affect this pump function There cannot be any leakage from the crankshaft between the crankcase halves or between the crankcase and the cylinder Always replace the sealing rings and gaskets when servicing the crankcase Disma...

Page 48: ...a hammer Do this while the crankcase half is still warm if possible Knock the crankcase half against a woo den block so that the ball bearing falls out Knock the crankcase half against a woo den block so that the ball bearing falls out Inspecting the crankshaft Inspect the large end of the connecting rod Inspecting the crankshaft The crankshaft cannot be reconditioned but must be replaced if it is...

Page 49: ...e axial play in or der to ensure good lubrication of the crank bearing among other things Inspect the small end of the connecting rod Inspect the small end of the connecting rod If seizure marks or discolouration are found in the bearing track the crankshaft must be replaced Assembly Mount the bearings in the crankcase halves Assembly Mount the bearings in the crankcase halves Heat the crankcase h...

Page 50: ...ck that the piston is turned so the ar row points towards the exhaust port Do not forget the spacers between the piston and the needle bearing Make sure that the gudgeon pin circlips are seated correctly in the slots Place the flywheel key in position in the crankcase keyway so that the flat surface is parallel to the centre line of the crank shaft Attach the flywheel Lubricate the piston and pist...

Page 51: ...7 50 Crankshaft and crankcase ...

Page 52: ..._________________54 Fuel system___________________________________54 Centrifugal clutch______________________________54 Angle gear ___________________________________55 Cylinder and piston ____________________________55 Crankshaft and crankcase _______________________55 Workshop equipment __________________________55 ...

Page 53: ... 76 502 50 83 01 501 60 02 03 505 69 85 70 522 43 18 01 502 02 61 02 531 03 06 23 502 50 18 01 502 71 14 01 502 50 18 01 522 43 18 01 522 43 18 01 510 13 89 01 502 51 34 02 List of tools Electrical system Centrifugal clutch Starter Fuel system Fuel system ...

Page 54: ...5 69 85 70 505 38 17 05 502 50 70 01 502 50 18 01 502 50 70 01 544 13 05 01 544 13 08 01 544 13 09 01 544 13 10 01 544 34 87 01 503 97 64 01 505 38 17 09 502 50 19 01 List of tools Angle gear Cylinder and piston Crankshaft and crankcase Workshop equipment Workshop equipment ...

Page 55: ...54 8 List of tools ...

Page 56: ..._______________________58 Ignition system________________________________58 Carburettor___________________________________58 Clutch _______________________________________58 Driving ______________________________________58 Dimensions___________________________________58 ...

Page 57: ...Manufacturer Walbro WYK Basic setting H needle turns 1 1 2 Idle speed rpm 2 500 Air filter type Foam plastic Throttle control type Forefinger Fuel consumption 720 g kWh Clutch 2 shoe clutch Diameter mm 53 5 Engage speed rpm 3 300 Driving Angle gear degrees 30 Angle gear gear ratio 1 1 46 Control drive disc inch 1 Shaft diameter mm 24 Drive axle diameter mm 7 Drive axle connections Splines splines ...

Page 58: ...11 535 83 26 2018W35 ...

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Husqvarna 226R, Workshop Manual

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