Husqvarna R135, R333, RX335, RJ333, RJ535 Workshop Manual
...
67 – German
Workshop manual
English
R135, R333, RJ333, RJ535, RJX335, RX335, RX535,
RXT535, FR335, FR336, FRD336, LS335, LS535, LX335
1
1
Starter
© Copyright Husqvarna AB, Sweden 2012
Workshop Manual
Brushcutter, Trimmer
Models
R RJ RJX RX RXT FR FRD LS LX
135 333 335 335 535 335 336 335 335
333 535 535 336 535
Contents
General recommendations ___________________________2
1. Starter _________________________________________3
2. Electrical system _________________________________9
3. Fuel system ___________________________________ 17
4. Centrifugal clutch ______________________________ 36
5. Angle gear ____________________________________ 41
6. Cylinder and piston _____________________________ 45
7. Crankshaft and crankcase ________________________ 55
8. Tools ________________________________________ 61
9. Technical Data _________________________________ 65
2
1
Starter
General recommendations
Bear in mind:
Do not start the machine without making sure the cut-
ting attachment and all the safety features are tted
and working properly.
To avoid burns, do not touch hot components, e.g. the
mu er before they have cooled su ciently.
Avoid getting fuel or oil on your skin or in your mouth.
Use a barrier cream on your hands. This reduces the
risk of infection and makes dirt easier to wash away.
Long term contact with engine oil can represent a
health hazard.
Never start the engine indoors. Exhaust fumes are
poisonous! They contain carbon monoxide, an odourless, poisonous and highly dangerous gas.
Wipe up oil spills from the oor immediately to avoid
slipping.
Do not use tools that are worn or t badly, for example
on nuts and bolts.
+ Always work on a clean bench.
+ Always work logically to ensure all parts are tted cor-
rectly and that nuts and bolts are tightened.
+ Use the special tools where recommended to be able
to carry out the work correctly and e ciently.
Fire risk
Handle fuel with respect as it is extremely in ammable.
Never refuel while the engine is running.
Do not smoke and ensure there are no open ames or sparks
in the vicinity.
Never start the engine if the machine is leaking fuel or if there
has been a spillage when refuelling. Allow the remaining fuel
to evaporate rst.
Make sure there is a working re extinguisher close at hand.
Do not try to extinguish a petrol re with water.
Poisonous fumes
When using cleaning agents read the instructions carefully.
Ensure there is good ventilation when handling petrol and
other volatile uids.
The engine’s exhaust fumes are poisonous. Test run the
engine outdoors.
Special tools
Some of the work described in this workshop manual requires special tools. In each section where this is necessary
there is a picture of the tool and an order number.
We recommend the use of special tools in order to avoid expensive damage to parts in question and personal injury and
to provide an e cient repair procedure.
Contact faces and gaskets
Ensure all surfaces are clean and free from gasket residue,
etc. When cleaning use a tool that will not damage the contact face. Any scratches or unevenness should be removed
using a at ne cut le.
Sealing rings
Always replace a sealing ring that has been dismantled.
The sensitive sealing lip can easily be damaged resulting in
inferior sealing capacity. Surfaces which the seal shall seal
against must also be completely undamaged. Lubricate the
sealing lip with grease before it is tted and ensure that it is
not damaged e.g. by shoulders and splines on a shaft. Use
tape or a conical sleeve as protection. It is important that
the sealing ring faces in the right direction for it to act as it is
intended.
The workshop used to carry out repairs must be equipped
with safety devices in accordance with local directives.
No one may carry out repairs without rst having read and
understood the contents of this Workshop Manual.
The boxes below can be found in appropriate parts of this
manual.
WARNING!
The warning box warns of the risk for
personal injury if the instructions are not
followed.
NOTE!
This box warns of damage to material if the instructions are not followed.
The machine is type approved for safety in accordance with
applicable legislative demands with the equipment speci ed
in the Operator’s Manual. 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.
3
1
Starter
1
Starter
Contents
Dismantling _______________________________________ 4
Assembly__________________________________________ 5
Assembling the starter with a start assistance spring ______ 5
Replacing the drive dogs _____________________________ 7
4
1
Starter
502 50 18-01
502 50 18-01
502 50 18-01
!
WARNING!
Wear protective glasses.
The return spring lies tensioned
in the starter and can y out
and cause personal injury with
careless handling.
WARNING!
Protective glasses should be worn when working on the starter to avoid injury to the
eyes if, for some reason, the return spring should y out.
!
Dismantling
Model 336
Remove 2 of the screws holding the
cover under the engine against the
starter.
Loosen the 3 screws that hold the
starter in place and remove the starter.
The cylinder cover does not need to be
loosened or detached.
Dismantling
Model 333/335
Remove the 4 screws and carefully
swing down the protective plate so far
that the starter can be lifted out.
The cylinder cover does not need to be
loosened or detached.
NOTE!
Ensure the bushings that guide the starter towards the fuel tank are not lost.
The starter equipped with a start assistance spring is dismantled in the same way
as described above. However, to remove the screw in the centre of the starter pulley
requires a 5 mm Allen key, e.g. 502 50 64-01.
Remove the bolt in the centre of the
starter pulley and remove the starter
pulley.
Remove the bolt in the centre of the
starter pulley. Lift the starter pulley carefully from the starter cover.
Loosen the spring tension. Loosen the spring tension.
Pull out the starter cord about 30 cm.
Brake the starter pulley with your thumb
and lift the cord as illustrated.
Let the starter pulley rotate backwards
slowly.
5
1
Starter
Assembly
Clean the component parts and assemble in the reverse order as set out for
dismantling.
Assembly
Clean component parts before
assembling.
Replace the return spring/starter pulley
and starter cord, if necessary.
Lubricate the spindle with a little grease
and t the starter pulley.
Position the washer and tighten the
screw.
NOTE!
The return spring and starter pulley
are supplied pre-assembled and
are tted in the starter housing as a
single unit.
Exercise care when opening the
packaging so that the spring does
not y out.
Assemble the starter pulley.
Assemble a new starter cord.
NOTE!
A new starter cord can be tted
without the need of dismantling
the starter!
Assemble a new starter cord.
Assemble a new starter cord. Slide it
into the slot on the starter pulley as
shown in the picture.
Make sure that the knot at the end of the
cord is as small as possible and that it is
pressed in the starter pulley!
Assembling the starter
with a start assistance
spring
Clean the component parts and assemble in the reverse order as set out for
dismantling.
Assembling the starter
with a start assistance
spring
Clean component parts before
assembling.
Replace the return spring/starter pulley
and starter cord, if necessary.
NOTE!
The return spring and starter pulley
are supplied pre-assembled and
are tted in the starter housing as a
single unit.
Exercise care when opening the
packaging so that the spring does
not y out.
6
1
Starter
A
B
C
D
E
502 50 64-01
Assemble the starter handle.
Tie a double knot on the starter cord and
fold under the free end.
Pull the knot fully into the handle.
Lubricate the spindle with a little grease
and t the starter pulley.
Move the starter cord through the guide
in the starter housing.
Assemble the starter pulley.
Place the start assistance spring (A) in
position.
Position the cover disc (B) over the start
assistance spring and make sure that
the spring pin enters the disc correctly.
Place the spacer (C) and washer (D) in
position in the hub on the cover disc (B).
Tighten the screw (E) in the centre of
the starter pulley.
Position the start assistance spring in
position in the starter pulley and assemble the other parts as in the illustration.
Tighten the screw in the centre of the
starter pulley.
7
1
Starter
502 51 49-01
Fit the starter on the engine body.
1. Check that the rubber bushings (A)
are in position in the starter housing.
2. Insert the small tab (B) on the
periphery of the starter under the
carburettor cover and swing the
starter in against the engine body.
3. Press the starter in against the
engine body.
4. Pull the starter handle and check
that the drive dogs engage.
5. Screw on the starter and the protective plate.
Tension the return spring.
Check the spring tension.
Tension 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 the starter pulley.
Now turn the starter pulley anticlockwise, 6 turns.
For starters with a start assistance
spring, the starter pulley must be turned
anti-clockwise 5 turns.
Check the spring tension. With the starter cord fully extended it should still be
possible to turn the starter pulley further,
at least a half turn.
Remove the circlip and replace any damaged drive dogs or springs, if necessary.
Remove the circlip holdings the drive
dog.
Lift out the drive dog and spring for
replacement.
Assemble in the reverse order as set
out for dismantling.
Check that the drive dogs move easily!
Replacing the drive
dogs
Dismantle the drive body.
Replacing the drive
dogs
Fit the puller 502 51 49-01 on the ywheel (see chapter 2 ”Electrical system”) and loosen the drive cup.
NOTE!
The nut is brazed onto the drive
cup.
Do not use, e.g. a pair of slip-joint
pliers to hold the drive cup. It can
easily be deformed so that the
drive dogs cannot move freely.
8
1
Starter
9
2
Electrical system
2
Electrical system
Contents
Checking the ignition spark ______________________ 10
Dismantling __________________________________ 12
Assembly_____________________________________ 14
10
2
Electrical system
502 51 91-01
502 71 13-01
333/335
336
The engine is equipped with an electronic ignition system completely without moving parts. Consequently, a
faulty component cannot be repaired, but must be replaced by a new component.
The spark in an electronic ignition system has a very short burn time and can therefore be interpreted as
weak and can be di cult to see while troubleshooting.
Make sure the stop switch is in the start
position (333/335).
Earth the spark plug on the cylinder
(333/335) or earth it using a steel wire
around a starter screw that is screwed
to the crankcase (336).
Give a sharp pull on the starter handle.
A spark should be seen between the
electrodes.
If no spark is seen test with test spark
plug no. 502 71 13-01.
If a spark then occurs, the spark plug is
faulty.
Try a new spark plug.
Checking the ignition
spark
Clean the electrodes and check the
electrode gap.
Checking the ignition
spark
Remove the spark plug and clean it from
soot deposits with the help of a steel
brush.
Check the electrode gap. It should be
0.5 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.
11
2
Electrical system
502 50 06-01
When there is still no ignition spark,
dismantle the short-circuit cable from the
stop switch.
Remove the connector by prying it up
out of the throttle with a knife.
Still no spark?
Check the short-circuit cable with the
help of an Ohmmeter.
Also see ”Dismantling” below.
Still no spark?
Check the ignition cable’s connection to
the spark plug cover.
Still no spark?
Check the spark plug connection.
Remove the spark plug cover and make
sure the ignition cable is not damaged.
Remove a segment of cable if required
to get su cient contact at the connection coil.
Use pliers no. 502 50 06-01 to make a
hole in the ignition lead.
When a part of the ignition lead has
been cut o it helps to use the pliers no.
502 50 06-01 to make a hole in the ignition lead to t the contact coil.
NOTE!
It is important that the tip of the
contact coil hits the centre of the
ignition lead to prevent sparking.
Attach the ignition coil to the ignition
cable.
Attach the ignition coil to the ignition
cable and ensure that the wire is folded
along the cable.
Slide the contact coil into the spark plug
cover.
TIP!
Lubricate the hole in the spark plug
cover so that it is easier to slide in the
contact coil.
12
2
Electrical system
502 51 34-02
0.3
336
333/335
Dismantling
The following components must be
dismantled for the ignition system to be
accessible:
The air lter cover, the spark plug, the
shield under the engine, the starter, the
cylinder cover and the cover over the
mu er.
Unhook the throttle cable from the
carburettor.
NOTE!
Do not lose the rubber bushings
tted between the starter and the
fuel tank.
Still no spark?
Check the air gap.
See ”Dismantling” below.
Still no spark?
Check the air gap between the ywheel
magnet and the ignition module. The
gap should be 0.3 mm.
Use a 502 51 34-02 feeler gauge.
See ”Dismantling” below.
Still no spark?
Check other cables and connections.
Still no spark?
Check other cables and connections
for poor contacts (dirt, corrosion, cable
breakage and damaged insulation).
Make sure that the cables are correctly
drawn and lie in the cable grooves.
Do not forget to check the cables in the
throttle too.
See chapter 3 “Throttle”.
TIP!
Use an Ohmmeter in order to easily
check if cable breakage has occurred,
due to pinching, for example.
Adjust the air gap.
Adjust the air gap as needed to the correct value.
• Loosen the bolts.
• Position the feeler gauge and press
the ignition module against the ywheel.
• Tighten the bolts and check the air
gap again.
If the spark plug still does not re, the
ignition system should be replaced.
13
2
Electrical system
F
G
E
E
E
336333/335
Remove the 3 screws (E) and swing the
engine body to one side.
Remove the 3 screws (E) and swing the
engine body to one side.
Dismantle the short-circuit cable from
the ignition module.
Dismantle the short-circuit cable from
the ignition module by removing the
screw (F) and prying o the at pin connector (G).
Option B
Lift out the ignition lead and short-circuit
cables from their guides.
Remove the 3 screws (E) and swing the
engine body to one side so the clutch
becomes accessible.
Option A
Loosen the screw and slide the cable
holder (B) forwards.
Remove the screws and slide the cover
(D) forwards.
Option A
Loosen the screw (A) and slide the cable holder (B) forwards on the shaft.
Remove the screws (C) and slide the
cover (D) forwards on the shaft.
14
2
Electrical system
502 51 49-01
502 51 49-01
502 50 18-01
Remove the nut holding the ywheel. Remove the nut holding the ywheel.
Fit the puller on the ywheel. Loosen
and remove the nut.
NOTE!
The completely at side on the
clutch should rest against the
washer closest to the ywheel.
Remove the ywheel. Dismantle the ywheel from the crank-
case using the puller
no. 502 51 49-01.
Gently knock the puller screw with a
hammer, if the ywheel sits tightly on the
crankshaft.
Assembly
Check that the cast key in the ywheel
and key way in the crankshaft are undamaged.
Fit the ywheel and centrifugal clutch.
Do not forget the washers (A).
Note the slots on the washer lie closest
to the ywheel. Align with the equivalent
pins on the ywheel.
Dismantle the ignition module and the
centrifugal clutch.
Remove the remaining screws (A)
holding the ignition module and both
screws (B) that hold the centrifugal
clutch.
Lift o the clutch, both support washers
and the ignition module.
15
2
Electrical system
502 51 34-02
0.3
Assemble the ignition module.
Adjust the air gap. It should be 0.3 mm
between the permanent magnets in the
ywheel and the ignition module.
Tighten the screws and do not forget
the ring cable lug under the outer screw.
Assemble other parts in the reverse
order as set out for dismantling.
NOTE!
Do not forget the rubber bushings between the fuel tank and the crankcase/
clutch cover and the fuel tank and starter.
Assemble the ignition module and adjust the air gap to 0.3 mm.
16
2
Electrical system
17
3
Fuel system
3
Contents
Air lter ________________________________________ 18
Tank venting ____________________________________ 19
Fuel lter _______________________________________ 19
Fuel pump ______________________________________ 20
Carburettor _____________________________________ 20
Throttle ________________________________________ 29
Start throttle speed ______________________________ 31
Carburettor settings ______________________________ 32
Fuel system
18
3
Fuel system
505 69 85-70
531 00 60-76
336
336333/335
333/335 336
In addition to the fuel tank and carburettor, the fuel system consists of the air lter, fuel lter and tank venting.
All these components interact so that the engine receives the optimal mixture of fuel and air to make it as
e cient as possible. Very small deviations in the carburettor setting or a blocked air lter have a large e ect
on the running and e ciency of the engine.
The carburettor can come from several di erent manufacturers on our models, but the function and repair
methods are essentially the same.
Air lter
Remove the air lter cover and lift o the
air lter.
The lter is manufactured of foamed
plastic and should be cleaned in tepid
soapy water.
A damaged lter should be replaced
with a new lter.
WARNING!
Do not clean not the lter
with petrol. Hazardous!
NOTE!
Do not blow the lter clean with
compressed air. It can be damaged.
Ensure that the lter is dry before
re tting it.
!
TIP!
Use Husqvarna’s cleaning agent Active
Cleaning no. 505 69 85-70.
Impregnate the lter with air lter oil. Impregnate the lter with air lter oil.
TIP!
Place the lter in a plastic bag and pour
about a tablespoon of air lter oil no.
531 00 60-76 into the bag.
Massage the oil into the air lter.
19
3
Fuel system
502 50 83-01
531 03 06-23
333/335
336
Fuel lter
The fuel lter can be removed through
the tank’s ll hole.
Fuel lter
The fuel hose in the tank contains a fuel
lter. It is accessible through the ll hole.
Pull out the lter with your ngers or
with help of tool 502 50 83-01.
Model 333/335
The fuel cap can be taken apart for clea-
ning.
Use a screwdriver and press o the
housing (A) that contains a rubber
diaphragm (B) and a lter (C) and cover
(D).
Blow the lter (C) clean, and the sintered lter (E), with compressed air and
mount the fuel cap in the reverse order
to how it was disassembled.
Make sure that the at surface on the
cover (D) is turned towards the diaphragm.
NOTE!
There is a small slit (F) in the
diaphragm (B) that becomes visible
when you carefully pull the edges
of the diaphragm. Check that the
edges of the slit are not damaged.
Replace diaphragm if necessary.
Model 336
The fuel cap can be taken apart for
cleaning.
Use a screwdriver and prise o the
housing (A).
Remove the nipple (B) using a small at
nosed pliers.
Blow the bleeding opening in the housing (A) clean with compressed air.
Blow clean both sintered lters (C) with
compressed air.
Assemble the fuel cap in reverse order
as set out for dismantling.
Make sure the gasket (D) is not damaged.
Tank venting
Tank venting takes place through the
fuel cap and needs to be functional for
the engine to work.
• Remove the air lter cowling and
dismantle the cylinder cover.
• Remove the fuel hose from the carburettor and empty the fuel from the
tank.
• Connect the fuel hose to pressure
tester no. 531 03 06-23.
• Pump up a pressure and vacuum of
50 kPa (0.5 bar) in the tank.
• The pressure should drop to 20 kPa
(0.2 bar) or revert to atmospheric
pressure within 45 seconds.
Tank venting
Check that the tank venting valve works
correctly.
Replace the fuel cap if the valve is
faulty.
20
3
Fuel system
333/335 336
333/335
Clean the lter externally if it is not too
dirty.
Replace the lter if required.
If the lter is not too dirty, its surface can
be cleaned with a brush.
Otherwise it must be replaced.
Check the fuel hose for cracks and
leaks.
Make sure that the lter’s connection
neck is inserted as far as possible into
the fuel hose and that the O-ring (model
333/335) is su ciently tight so that the
lter cannot slide o the hose.
NOTE!
Note how the pressure rods (2) and
(3) are tted to make it easier when
assembling after a service.
Carburettor
Dismantling
Blow clean the carburettor compartment
and remove the screws holding the carburettor and the air lter housing.
Carburettor
Dismantling
1. Remove the air lter cover and cylinder cover and blow clean the carburettor compartment using compressed
air.
2. Remove the three screws holding the
carburettor and the air lter housing.
NOTE!
Do not lose the washer under the
head of the upper screw.
3. Lift o the carburettor and the air lter
housing from the cylinder and disconnect the throttle cable, the fuel hose
from the carburettor and pull up the
fuel hose, which joins the tank and the
fuel pump, from the tank.
Remove the remaining fuel hose (1) and
both pressure rods (2) and (3).
Fuel pump
The fuel pump facilitates cold starts.
The pump cannot be repaired and must
be replaced if it stops working.
Note how the fuel hoses are connected
to simplify assembly.
Fuel pump
The fuel pump has the task of facilitating
the start of the engine when cold. The
pump lls the carburettor with fuel
before attempting to start the engine.
This also prevents vapour bubbles from
blocking the narrow fuel channels.
If the pump does not work it must be
replaced.
Note how the fuel hoses are connected
to simplify assembly.
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