Husqvarna 165R Workshop Manual Download

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Workshop manual

Clearing Saw

Model

101 88 04-26

165R

For Husqvarna Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

Summary of Contents for 165R

Page 1: ...Workshop manual Clearing Saw Model 101 88 04 26 165R For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 2: ...a Specialtools Fuelsystem carburetor Electricalsystem Cylinder piston Crankcase crankshaft Starter Handlebars controls Enginemounting driveshaft Transmission system For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 3: ... Fuel mixture 40 1 25 oil With Husqvarna Twostroke Oil 2 1 50 Husqvarna type BU 75 Husqvarna type Maxi 9 110 10 8 kg Empty clearing saw without harness and transit protection for saw blade EPOgrease or Husqvarna special grease order number 5025127 01 Cylinderclass Pistonclass A A B B c c If absolutely necessary a class A piston may be used with a class B cylinder Fig 1 1 NOTE A class B piston must...

Page 4: ...e exhaust Fig 2 1 Starter It should be possible to turn the cord pulley about another half turn when the starter cord is fully with drawn Fig 2 2 Carburetor Pressure 0 03 MPa 0 3 kgf cmz 4 3 psi Leakage No leakage permitted Tools 5025038 01 Pressure tester 5025045 01 Spacer sleeve 35 mm 5025047 01 Sealing plate inlet 5025048 01 Sealing plate exhaust Fig 2 3 2 1 For Husqvarna Parts Call 606 678 962...

Page 5: ... of 1 part oil to 20 PWk PdrOi 5Yo k recommended For Husqvarna Two stroke Oil a mixture of 1 part oil to 50 parts petrol 2Yo is recommended The table below shows the different mixture proportions Mixture table Litres For 2Y0 For hyo For 5Y0 of petrol mixture mixture mixture Litres of Litres of Litres of oil oil oil 5 0 1 0 2 0 25 10 0 2 0 4 0 50 15 0 3 0 6 0 75 20 0 4 0 8 1 00 25 0 5 1 0 1 25 2 2 ...

Page 6: ...165 R ServiceData Q Tighteningtorques Nm Lubricationpoints II II II aclo 2 3 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 7: ... 5025023 01 NV 10 mm Nut driver 5025025 01 Holdfast complete Ill5025026 01 Puller complete with screw B 5027005 01 6is Q 0 0 5025037 01 Vacuum tester complete 5025038 01 Pressure tester complete 5025042 01 Lithium grease 250 g 5025045 01 Spacer sleeve 35 mm 5025047 01 Sealing plate inlet 5025048 01 Sealing plate exhaust 5025049 01 Pliers centrifugal clutch 3 1 For Husqvarna Parts Call 606 678 9623...

Page 8: ...xtractor sealing ring 5025079 01 Sealing ring assembly sleeve 5025083 01 Hook for tank weight 5025086 01 NV 3 mm 5025087 01 NV4 mm 5025088 01 NV 5 mm Socket driver with ball 5025090 01 Jet Pac spray gun complete with touch up paint 5025091 01 Touch up paint orange 1 8 Iitre 5025092 01 Propellant gas for Jet Pac 5025102 01 Assembly jig 5025103 01 Special fixture 3 2 For Husqvarna Parts Call 606 678...

Page 9: ...01 Glue 5025107 01 Epoxy adhesive 5025108 01 Loctite AA normal locking force 5025109 01 Loctite AAV high locking force 1 5027004 01 M12 Screw for puller 3 3 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 10: ...nail holding the plastic sleeve in posi tion over the adjusting screws and remove the sleeve Clean the outside of the carburetor Fig 4 4 Back off the four screws holding the diaphragm cover in place and remove the cover Remove the diaphragm Note that the centre stud of the diaphragm enters a fork shaped opening in the needle valve lever Fig 4 5 Connect pressure tester No 5025038 01 to the fuel in ...

Page 11: ...ket is undamaged Back off the two adjusting screws and remove the cover over the pump diaphragm Remove the diaphragm and gasket Fig 4 10 Fig 4 8 Carefully remove the fuel filter from the carburetor hou sing using a sharp object Checkingthe carburetor A Pump Clean the fuel filter carefully using compressed air Clean all fuel passages and chambers using compres sed air Inspect the pump diaphragm for...

Page 12: ...ack in place Check that it is the right way round with the flared collar upwards Place the pump diaphragm on the carburetor housing and then the gasket and cover Tighten the four cover screws alternately B Meteringsystem Fit new blank plugs Press them into place by means of suitable pin punches or the like for the large plug punch diameter 8 mm for the small plug punch diameter 4 mm NOTE Do not pr...

Page 13: ... adjusting screws and secure it in place with the small nail Fig 4 15 Set the choke flap in the open position Open the throttle flap fully by pressing on the lever with your index finger Connect the fuel line and check that it has no kinks that may interrupt the supply of fuel Fit the air cleaner in place Carburetor tuning A Basicsetting Before tuning the carburetor proceed as follows Clean the ai...

Page 14: ...t the engine responds If it does not unscrew the L needle by an amount cor responding to about three minutes on a clock face Try again C Adjustingthe highspeed needle H Fig 4 19 G A Fuelsystem carburetor Run the engine at maximum speed by holding the throttle control firmly open If the setting is correct the engine should four stroke Reduce engine speed by slowly screwing in H needle until fourstr...

Page 15: ...rottle opened needs choke x x x x x Mixture grows too weak x x x Receives no fuel x x Hard to adjust x x x Mixture too rich x No idle x Abnormal needle setting x x x I I I I I I I I I I x 1 x x x x 4 6 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 16: ...secondary winding of the ignition coil by means of SEM ignition system tester No 5025124 01 Connect the earth lead of the instrument to the cylinder for example and the other lead to the plug lead The instrument should then give a reading when set for resistance measurement Remove the flvwheel and ianition coil see B Dis mantling Tes the ignition coil under load Note that different makes of igniti...

Page 17: ...OTE Rest the flywheel on a clean surface to avoid metal filings or metal objects being attracted to the magnets Fig 5 8 Remove the sparking plug cap Grasp the connecting spring inside the cap with a pair of flat nosed pliers e g 50250 06 01 and withdraw spring and lead A few drops of oil applied to the inside of the cap will facilitate reassembly Then unhook the spring from the lead Disconnect the...

Page 18: ...ecuring the armature plate Fit the flywheel note the key slot and other components in re verse order to removal Fig 5 1 1 Use special pliers No 5025006 01 when fitting the sparking plug cap to the plug lead to ensure satisfactory connection between contact spring and lead We recommend applying grease No 5025042 01 to both ends of the plug lead where it is connected to the sparking plug cap and the...

Page 19: ...aside and back off the screws retaining the silencer Note the two screws securing the bottom of the silencer to the crankcase Fig 6 2 Fig 6 3 Place a cloth in the crankcase opening to prevent dirf and foreign objects from dropping into the crankcase Remove the gudgeon pin retaining rings using a pair of flat nosed pliers and press the gudgeon pin out with a suitable pin punch Scrape the carbon dep...

Page 20: ...y Piston ring worn Check the wear by positioning the ring in the lowest part of the cy inder The distance between the ends of the piston ring should not exceed 0 6 mm Also check that the piston ring has lost none of its springiness Assembly Check that the piston and cylinder are marked with the Use a suitable drift to centre the piston opposite the same class designation see Fig 1 1and the classif...

Page 21: ... Rotate the crankshaft to check that the piston can move freely Secure the cylinder by tightening the four screws alter nately Fit the silencer in place Do not forget the securing plate for the screws in the cylinder nor the two screws holding the bottom of the silencer to the crankcase Fit the carburetor and air cleaner in place and recon nect the fuel line Make sure that the heat screen is corre...

Page 22: ...rankcase from the drive shaft if necessary by striking it lightly with a plastic mallet Fig 7 4 Fig 7 2 Remove the starter and fit holdfast No 5025025 01 to the flywheel Remove the centrifugal clutch left hand thread Note the shim inside the clutch Back off the five screws holding the crankcase halves together Heat the bearing seats carefully to a temperature of about 130 C with a blowlamp They sh...

Page 23: ... bearing seat Check that the correct crankshaft journal is mounted and that the ball bearing abuts against the bottom of the bearing seat Fig 7 8 Smear a little grease on the magneto side sealing surfa ce to keep the gasket in position Fit a new gasket Heat the drive side crankcase half in the same manner as be fore and press it down over the crankshaft and the magneto side Check that the locating...

Page 24: ...fit the sealing ring in the holder The dust exclu ding tongue should face outwards 2 Fit the O ring in the bearing seat outside the ball bea ring 3 Fit sealing ring assembly socket No 5025053 01 on the crankshaft 4 Push the sealing ring holder into position and tighten the three screws Mount the centrifugal clutch onto the crankshaft left hand thread Inspect the thrust bearing in the centre of the...

Page 25: ...w and washer in the centre of the cord pulley Remove the bearing sleeve Fig 8 5 If necessary attach a new starter cord to the pulley Make sure that the cord stop is fitted correctly in the pulley so that the tip of the screw points outwards from the pulley Mount the pulley in the starter housing making sure that the return spring engages with the pul ley Mount the bearing sleeve washer with the re...

Page 26: ...pulley Checking Pullthe startercordall the wayout It shouldnowbe possibleto rotatethe pulleyat least anotherhalfturnbeforethe springbottoms Fit the starter to the clearing saw and check that the driver hooks engage with the pulley Adjust the engagement position by means of a series of slight jerks with the starter handle o 0 Starter 0 8 2 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www m...

Page 27: ...te the handlebar tube until the throttle control is in the desired position Tighten screw A Fig 9 2 Fig 9 3 Remove the cylinder casing allowing the throttle lever to be seen Turn the throttle control cable by hand until the throttle lever just touches the choke lever Note that the choke control should be in the open position Tighten screw B Fig 9 2 Make sure that the two end positions of the throt...

Page 28: ... a l 4 turn at a time as the spring may otherwise be damaged Adjust the throttle control cable as above k Fig 9 5 If it is not possible to adjust the spring tension it may be because the spring has jumped out of position or has become deformed In such case disconnect the throttle control cable from the handlebar and remove sleeve C Inspect the return spring and fit a replacement if neces sary Then...

Page 29: ...hoke control Apply a few drops of Loctite to the screws and tighten the engine to the clutch housing NOTE It is extremely important to ensure that the four screws are properly tightened Connect the short circuiting cable to the stop contact Fit the cylinder casing in place Clutchhousing suspensiontube Dismantling Fig 10 3 Clamp the clearing saw in fixture No 5025103 01 Separate the engine unit fro...

Page 30: ...e until the vibration dampers are ex posed Fig 10 7 Fig 10 5 Back off the screws securing the vibration dampers Fig 10 6 Back off the five screws securing the clamp to the handle bars and also the locking screw see Fig 9 1 Back off the clamping screw and the two screws in the vibration dampers Slide the holder for the vibration dampers along the drive shaft tube until the dampers are exposed Back ...

Page 31: ...rings This may give rise to vibration and in the worst case seizure of the bearings Assembly Assemble the drive shaft tube in reverse order to dis mantling NOTE It is extremely important to ensure that the drive shaft tube abuts against the angle gear and that the stop screw is properly tightened 10 3 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 32: ...ghtly to the crankshaft that it is difficult to remove merely by striking the socket wrench with a hammer against the compression resist ance of the engine In such cases there is a remedy Remove the starter and fit holdfast No 5025025 01 to the flywheel se section 5 Inspection Inspect the clutch centre spokes and the centrifugal weights for wear The weights should have a minimum of 1 mm metal at t...

Page 33: ...amping screws and the stop screw see Fig 10 9 Withdraw the angle gear from the drive shaft tube Remove the oil filler plug and drain off any remaining oil in the gear housing Removalof lowerbearinghousing andgearshaft Heat the angle gear with a blowlamp to approx 130 C Clamp the angle gear in a vice with soft jaws Fit puller No 5025065 01 Prevent the shaft from rotat ing by means of an adjustable ...

Page 34: ...n the gear housing Make sure that the teeth engage as intended Fit extractor No 5025063 01 Heat the gear housing with a blowlamp to about 130 C Clamp the gear housing in a vice Quickly press the bearing housing in all the way Leave the puller in place until the gear housing has cool ed down to avoid all likelihood of dislodging the bearing housing Unscrew the puller and secure the bearing housing ...

Page 35: ...h grease until it emerges at the upper bearing housing Use type EP Ogrease as listed in the table of recom mended lubricants or Husqvarna angle gear grease No 5025127 01 RECOMMENDED LUBRICANTS BP HT EP00 ESSO Fibrax EP 370 Gulf Gear housing grease Mobil Mobilplex 45 Shell Alvania EPW O Texaco Marfak 00 11 4 For Husqvarna Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

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Husqvarna 165R, Workshop Manual

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