For Husqvarna Parts Call 606-678-9623 or 606-561-4983
Brush Cutters, Trimmers,
Pruners, Pruning Saws,
Hedge Trimmers, Ice Drills,
Blowers
Workshop Manual
101 90 74-26
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Workshop Manual
Brush cutters, Trimmers,
Pruners, Pruning saws, Hedge
trimmers, Ice drills, Blowers
Contents
General recommendations ______________________ 2
1. Starter __________________________________ 3
2. Ignition system ___________________________ 25
3. Fuel system _____________________________ 39
4. Centrifugal clutch _________________________ 81
5. Angle gear _____________________________ 107
6. Cylinder and piston ______________________ 119
7. Crankshaft and crankcase _________________ 147
8. Hydraulic unit ___________________________ 181
9. Cutting equipment _______________________ 191
10. Tools__________________________________ 209
The Manual covers the models:
265, 250, 252, 240/245
225 / 232 / 235 / 240 RBD
322/325
122, 32, Mondo
250PS, 235 P
225 H 60 / 225 H 75
225AI15, 225AI25
18H, 140B, 141B
132HBV, 225BV, 225HBV
© Copyright Husqvarna AB, Sweden
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1
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General recommendations
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 first having read and
understood the contents of this Workshop Manual.
The boxes below can be found in appropriate parts of this
manual.
WARNING!
!
NOTE!
This box warns of damage to material if the instruc-
tions are not followed.
The machine is type approved for safety in accordance with
applicable legislative demands with the equipment specified 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.
The warning box warns of the risk for personal injury if the instructions are not followed.
Bear in mind:
● Do not start the engine without the clutch drum and
driveline fitted as the clutch can become detached and
cause severe personal injury.
● Do not touch hot components, e.g. the muffler and clutch
before they have cooled sufficiently to avoid burns.
● 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!
● Wipe up oil spills from the floor immediately to avoid
slipping.
● Do not use tools that are worn or fit badly , for example on
nuts and bolts.
● Always work on a clean bench.
● Always work logically to ensure all parts are fitted correctly
and that nuts and bolts are tightened.
● Use the special tools where recommended to be able to
carry out the work correctly and efficiently.
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 extinguisher close at hand.
Do not try to extinguish a petrol fire with water.
Poisonous fumes
When using cleaning agents read the instructions carefully.
Ensure there is good ventilation when handling petrol and other
volatile fluids.
The engine's exhaust fumes are poisonous. T est run the engine
outdoors.
Special tools
Some of the work described in the 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 efficient repair procedure.
502 51 03-01
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 flat
fine cut file.
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 fitted 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.
2
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Starter
1.
Contents
Dismantling
General ______________________________________ 4
Model 265
Dismantling, assembly __________________________4
Model 250/252
Dismantling, assembly __________________________7
Model 240/245
Dismantling, assembly __________________________9
Model 225, 232, 235, 240
Dismantling, assembly _________________________11
Model 322, 325
Dismantling, assembly, replacement of the drive dogs ___ 13
Model 122
Dismantling, assembly _________________________15
Model 32, Mondo, Mondo Mega
Dismantling, assembly _________________________17
Model 18H
Dismantling, assembly _________________________21
Model 140B, 141B
Dismantling, assembly _________________________22
Assembly, general ____________________________24
Replacing the drive dogs _____________________24
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!
Starter
WARNING!
Protective glasses must be w orn when working on the starter to prevent injury
to the eyes, if for some reason, the return spring should fly out.
Dismantling
General
Dismantle the starter from the engine
body.
Dismantling
General
Remove all bolts and lift off the starter.
On some models the cylinder cover and
tank filler cap must be removed.
Model 265
Dismantling
Release the spring pressure.
Remove the screw and washer in the
centre of the starter pulley and bearing
sleeve.
Lift out the starter pulley.
Model 265
Dismantling
Release the spring pressure. Pull out the
starter cord approx. 30 cm.
Hold the starter pulley with your thumb
and place the cord in the cut-out on the
starter pulley rim.
Let the starter pulley slowly recoil.
NOTE!
Stop the spring with your thumb.
WARNING!
!
Remove the screw and washer in the
centre of the starter pulley and bearing
sleeve.
Lift out the starter pulley carefully so that
the spring does not follow and fly out.
Exercise care so that the
screw tip on the cord attachment does not injure
your thumb.
WARNING!
Wear protective glasses.
!
4
The return spring can fly
out and cause personal
injury.
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Starter
Remove the spring from the starter housing.
Assembly
Insert a new spring in the starter housing.
1
Remove the spring from the starter housing by knocking it against a bench with the
spring facing downwards.
WARNING!
!
Assembly
Fit a new return spring if necessary.
Let the spring retainer ring remain in place.
1. Place the spring over its seating in the
starter housing
2. Push the spring into its right position
using your thumb and let the retainer
ring slide off the spring.
3. Lubricate the spring with a few drops
of oil.
Wear protective glasses.
NOTE!
Do not forget the Pertinax disc be-
tween the spring and the starter
housing.
B
WARNING!
!
A
Check the starter pulley's bearing.
If necessary replace the sleeves (A) and
(B).
If necessary replace the starter cord.
Check the starter pulley's bearing. If it is
heavily worn the bearing sleeve (A) can
be replaced.
Cut out the sleeve and press in a new
sleeve.
If there is still too much play on the bearing a new metal sleeve (B) should also be
fitted.
If necessary replace the starter cord.
Thread the new cord through the hole in
the starter pulley as shown in the illustration and screw the plastic cube on the end
of the cord. Let it protrude approx. 3 mm
and melt it using a soldering iron to ensure a secure fastening is obtained.
Wear protective glasses.
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1
Starter
Wind the cord around the starter pulley
about 3 turns clockwise and position the
pulley in the starter housing.
Fit the washer and screw that hold the
starter pulley.
B
Tip!
The knot on the starter cord in the handle
can be difficult to undo. It is easier if you
place the knot on a hard surface and hit it
with a hammer.
Wind the cord around the starter pulley
about 3 turns clockwise
pulley in the starter housing.
Check that the return spring grips the
starter pulley hub correctly.
Lubricate the bearing sleeve (B) with a
few drops of oil and insert the starter
pulley.
Fit the washer and screw.
Use Loctite on the screw.
and position the
Fit the starter handle on the cord.
Tension the return spring.
Insert the cord through the cord guide in
the starter housing and anchor it in the
starter handle by tying a knot.
Fold down the free ends and pull the knot
fully into the starter handle.
To tension the return spring pull out the
starter cord fully and lift it into the cut-out
in the starter pulley.
Hold the pulley using your thumb then
tension the spring by turning the starter
pulley clockwise approx. 2 turns.
6
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Max
+ 1/2 r
Starter
Check the spring tension.
Model 250
Dismantling
Release the spring tension.
Remove the starter pulley.
1
Check the spring tension.
It should be possible to turn the starter
pulley at least a further half turn with the
starter cord fully extended
Model 250
Dismantling
Release the spring tension in the same
way as described for model 265.
Remove the screw in the centre of the
starter pulley and lift out the pulley.
.
Carefully remove the spring cassette so
that the spring does not fly out.
Check the starter pulley and starter housing for wear and damage.
Remove the screws and lift out the spring
cassette.
WARNING!
!
Despite the spring sitting in a cassette it
can still fly out when the cassette is pried
from the guide pin when inserting the
cord in the starter housing.
Check the following:
1. Wear on the drive pins on the starter
2. Nut in the nut pocket is in position and
3. Cord entry in the starter housing. If
Wear protective glasses.
pulley.
If necessary replace the starter cord.
the thread is undamaged.
worn the housing should be replaced.
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1
Starter
Assembly
Fit a new spring cassette if necessary.
Fit the spring cassette in the starter housing.
Assembly
Lubricate the return spring with a few
drops of oil or a cold resistant grease.
Ensure the spring has been pressed down
to the bottom of the cassette especially at
the fastening points.
Press the spring cassette into the starter
housing and tighten the screws.
Check that the end of the spring is approx.
3 mm from the spindle to help assembly
of the starter pulley.
Lubricate the surface of the cassette with
oil or cold resistant grease.
Fit a new starter cord. Fit a new starter cord.
Tie a small knot on the cord and melt the
ends of the cord so that is does not fray.
Wind the cord approx. 3 turns anticlock-
on the starter pulley.
wise
Tip!
First thread the cord straight through the
hole in the starter pulley and then back
again and out through the slot.
Fit the starter pulley . Lubricate the spindle in the starter hous-
ing with a few drops of oil and position the
starter pulley and tighten the screw.
Fit the starter handle as described for
model 265, but tie a double knot as the
cord is lighter.
8
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Max
Starter
Tension the return spring. To tension the return spring.
Wind the cord 2 turns anticlockwise
around the hub on the starter pulley and
pull out the starter handle until the cord is
extended.
Repeat the procedure once more.
Check the spring tension.
NOTE!
With the starter cord fully extended it
must still be possible to turn the starter
at least a further half turn.
pulley
1
+ 1/2 r
Models 240/245
Dismantling
Release the spring.
Remove the starter pulley.
Lift out the spring cassette. The spring cassette sits freely in the
Models 240/245
Dismantling
Release the spring tension as described
for model 265.
Remove the screw and washer and lift out
the starter pulley.
WARNING!
!
starter housing and can easily be lifted
out to be replaced.
Wear protective glasses.
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1
Starter
Assembly
Check the starter housing for wear and
damage.
Fit the spring cassette.
Anchor the starter cord in the starter
pulley and wind it approx. 4 turns clock-
wise onto the pulley.
Assembly
Check the cord guide in the housing. If it
is worn the starter housing must be replaced.
Lubricate the spring with a few drops of oil
and position the spring cassette in the
starter housing.
Tie a small knot on the cord and seal the
ends by melting the cord ends, e.g. with a
soldering iron.
Anchor the starter cord in the starter
pulley and wind it about 4 turns clock-
around the pulley .
wise
Fit the starter pulley in the starter housing.
Fit the starter handle on the cord. Fit the starter handle as described for
Lubricate the bearing spindle with a few
drops of oil and fit the starter pulley in the
starter housing.
Position the washer and tighten the screw.
model 265, but tie a double knot as the
cord is lighter.
10
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Max
Starter
Tension the return spring. To tension the return spring
Wind the cord 2 turns clockwise around
the hub on the starter pulley and pull out
the starter handle until the cord is fully
extended.
Repeat the procedure once more, but
only wind the cord 1 turn around the hub.
Check the spring tension. Check the spring tension.
NOTE!
With the starter cord fully extended it
must still be possible to turn the starter
pulley at least a further half turn.
1
+ 1/2 r
Models 225, 232, 235,
240
Dismantling
Release the spring tension and dismantle the starter pulley.
Remove the spring cassette. Remove the screw and lift out the spring
Models 225, 232, 235,
240
Dismantling
Release the spring tension as described
for model 265.
Remove the screw and washer and lift out
the starter pulley.
cassette from the starter housing.
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!
WARNING!
Wear protective glasses.
11
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1
Starter
Assembly
Check the starter housing for wear and
damage.
Fit a new spring cassette if necessary.
Fit a new starter cord. Fit a new starter cord. Tie the smallest
Assembly
Check the cord entry.
If it is worn the starter housing must be
replaced.
Lubricate the return spring with a few
drops of oil and fit the cassette in the
starter housing.
NOTE!
The end of the spring should be 3–
4 mm from the spindle to help assembly of the starter pulley.
knot possible on the cord and melt the
ends to stop it from fraying.
Wind the cord about 3 turns anticlock-
on the starter pulley.
wise
Position the starter pulley in the starter
housing and fit the washer and screw.
Max
Fit the starter handle. Fit the starter handle as described for
model 265.
Tension the return spring by winding the
starter cord 2 turns anticlockwise around
the hub on the starter pulley.
Repeat the procedure once more, but
with the cord only wound once around the
hub.
Check the spring tension.
NOTE!
With the starter cord fully extended it
must still be possible to turn the starter
pulley at least a further half turn.
12
+ 1/2 r
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Starter
1
Models 322, 325
Dismantling
Remove the 3 bolts and lift off the starter.
NOTE!
Ensure the bushings (A) that guide the starter towards the fuel tank are not lost.
A
Offload the spring tension.
Remove the screw from the centre of the
starter pulley and lift off the starter pulley .
Offload the spring tension in the same
way as described for model 265.
Remove the screw in the centre of the
starter pulley. Carefully lift out the starter
pulley from the starter housing.
Assembly
Clean the component parts and assemble in the reverse order as set out for
dismantling.
Assemble the starter pulley.
Assemble a new starter cord.
NOTE!
A new starter cord can be fitted
without the need of dismantling the
starter!
WARNING!
!
The return spring lies tensioned in
the starter and can fly out and
cause personal injury with careless handling.
Assembly
Clean component parts before assembly.
Replace the return spring/starter pulley
and starter cord, if necessary.
NOTE!
The return spring and starter pulley
are supplied pre-assembled and are
fitted in the starter housing as a
single unit.
Exercise care when opening the
packaging so that the spring does
not fly out.
Lubricate the spindle with a little grease
and fit the starter pulley.
Position the washer and tighten the screw.
Assemble a new starter cord. Slid 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!
Wear protective glasses.
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1
Starter
Assembling the starter handle.
Tension the return spring
Check the spring tension.
Fit the starter on the engine body.
Do not forget the guide sleeves for the fuel
tank.
Assemble the starter handle in the same
way as described for model 265, but tie a
double knot as the cord is lighter.
Tension the return spring. Pull out the
starter cord fully and lift it out of the cutout in the starter pulley.
Now turn the starter pulley anticlock-
wise, 6 turns.
Check the spring tension. With the starter
cord fully extended it should still be possible to turn the starter pulley further,
least a half turn.
at
Replacing the drive dogs
Dismantle the drive body.
504 91 06-05
Remove the circlip and replace any damaged drive dogs or springs, if necessary .
Replacing the drive dogs
Fit the piston stop no 504 91 06-05 in the
spark plug hole and loosen the nuts holding the drive body.
Remove the circlip holding the drive dog.
Lift out the drive dog and spring for re-
placement.
Assemble in the reverse order as set out
for dismantling.
14
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Starter
Model 122
2
1
Dismantling
Remove the covers from the muffler and
cylinder.
Dismantle the starter from the engine
body.
Model 122
Dismantling
Y ou must first remove the covers over the
muffler and cylinder to be able to dismantle the starter.
Remove the screw (1), pull out the lower
edge of the cover and lift it off.
Remove the screw (2) and lift off the
cylinder cover.
Remove the screws and lift off the starter
from the engine body.
1
Remove the starter hub from the crankshaft.
Replace the drive dog if it is damaged or
worn.
Unscrew the hub from the crankshaft.
Use a hammer and punch to loosen the
hub if necessary.
NOTE!
The nut is brazed on the drive.
The drive dog and its spring can easily be
replaced if damaged or worn.
Squeeze together the drive dog's axle
stud with pliers when dismantling.
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1
Starter
Release the spring tension and dismantle starter pulley.
Assembly
Fit a new return spring in the starter unit.
Release the spring tension as described
for model 265.
Remove the screw and washer and carefully lift out the starter pulley so that the
return spring does not fly out.
WARNING!
!
Assembly
Fit a new return spring in the starter unit.
Press the spring down correctly on the
fastener and lubricate with a few drops of
oil or cold resistant grease.
Ensure the ends of the spring are 2-3 mm
from the spindle.
Wear protective glasses.
Fit a new starter cord and position the
starter pulley in the starter housing.
Fit the starter handle.
Tension the return spring.
WARNING!
!
Fit a new starter cord. Tie the smallest
knot possible on the cord but leave free
an end of approx. 10 mm.
Press the free end into the cut-out in the
pulley hub reinforcement.
Wind the cord about 4 turns clockwise
(seen from the rear) on to starter pulley.
Position the starter pulley in the starter
housing and fit the washer and screw.
Fit the starter handle as described for
model 265, but tie a double knot on the
cord.
Lift up the starter cord from the cut-out
and wind it 2 turns
the hub on the starter pulley . Pull out the
starter handle until the cord is fully extended.
Repeat the procedure once again.
Wear protective glasses.
anticlockwise
around
16
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+ 1/2 r
Max
Starter
Check the spring tension.
Models 32, Mondo,
Mondo Mega
Dismantling
Remove the screws that hold the throttle
trigger.
1
NOTE!
With the starter cord fully extended it
must still be possible to turn the starter
pulley at least a further half turn.
Fit the hub, starter and covers in the
reverse order set out for dismantling.
Models 32, Mondo,
Mondo Mega
Dismantling
Remove the screws that hold the throttle
trigger and slide it along the shaft as far as
the throttle cable and electrical cables will
allow.
Lift out the throttle cable. Move the throttle trigger forward and lift
the throttle cable out of the trigger.
Disconnect the electrical cables.
Remove the shaft complete with handles.
Disconnect the electrical cables by the
engine body and remove the 4 screws
(models Mondo and Mondo Mega have 3
screws) that hold the shaft and handle on
the starter housing.
Lift off the shaft.
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1
Starter
Dismantle the centrifugal clutch.
Dismantle the starter.
Undo the nuts holding the centrifugal
clutch and lift off the clutch and the large
washer.
Remove the 4 screws and lift off the
starter.
Model 32
Pull out the electrical cables from the
starter housing using flat nose pliers.
Model Mondo
Also dismantle the screw by the spark
plug.
Remove the two locking plates that hold
the starter pulley axially.
Release the spring tension. Release the spring tension.
Remove the two locking plates that hold
the starter pulley axially.
Pull out the starter cord about 30 cm and
place the cord in the cut-out on the edge
of the starter pulley.
18
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Starter
Let the starter pulley slowly rotate backwards.
Lift off the starter pulley.
Remove the return spring from the starter
housing.
1
Let the starter pulley slowly rotate backwards (anticlockwise) and then lift off the
pulley.
NOTE!
Stop the rotation using your thumb.
WARNING!
!
Exercise great care when removing the
starter spring.
The spring is tensioned inside a sheet
cassette, nevertheless it can still easily
fly out when dismantled.
Take care so that your
thumb is not injured by
the cord's fastening
screw.
Assembly
Insert a new spring cassette in position in
the starter housing.
Replace the starter cord and attach it as
shown in the diagram.
WARNING!
!
Assembly
Lubricate the return spring with a few
drops of oil and position the new spring
cassette in the starter housing.
If the spring, despite your being careful, has
flown out reposition it again in the cassette
with the end turned as shown in the picture.
!
Attach the new starter cord to the starter
pulley and wind it about 3 turns clock-
wise
Wear protective glasses.
WARNING!
Wear protective glasses.
around the pulley .
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1
Starter
Fit the starter pulley. Lubricate the pulley spindle with a few
drops of oil.
Ensure the end of the spring is about 2–
3 mm from the spindle and position the
starter pulley.
NOTE!
Do
not
tighten the locking plates
that hold the starter pulley axially.
Fit the starter handle.
Fit the starter handle as described for
model 265.
Tie a double knot as the cord is lighter
than on model 265.
Max
+1/2 r
Tension the return spring. Tension the return spring.
● Pull out the cord approx. 30 cm and
stop the starter pulley with your thumb.
● Lift the cord up from one of the cutouts on the starter pulley.
● Wind the cord 2 turns clockwise
around the hub on the starter pulley.
● Pull out the starter cord fully.
Repeat the spring tensioning and fit the
locking plates.
Repeat the spring tensioning once more.
Ensure the starter pulley can still be turned
at least a further half turn with the cord
fully extended.
Tighten the locking plates that hold the
starter pulley axially.
NOTE!
Model 32 has a thin spacer under
the plates.
20
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Starter
Model 18H
Dismantling
Dismantle the air filter, throttle cable and
carburettor.
Remove the 4 screws holding the engine
body and gear housing.
Dismantle the centrifugal clutch. Assemble the piston stop no. 504 91 06-
Model 18H
Dismantling
The starter is positioned between the
crankcase and the cutting equipment
drive.
First dismantle the spark plug, air filter,
throttle cable and carburettor.
Turn the mower upside down so that the
screws holding the engine body are accessible. Remove the 4 screws.
05 in the cylinder.
Unscrew the centrifugal clutch. First
loosen it using a hammer and punch,
anticlockwise.
1
504 91 06-06
Dismantle the starter from the engine. Dismantle the starter.
Remove the 5 screws holding the starter
housing
Lubricate the ignition cable with a few
drops of oil and remove the rubber grommet in the cover.
Lift off the starter housing.
The following procedures are the same as for models 32, Mondo:
Remove the locking plates holding the starter pulley axially.
Offload the spring tension.
Dismantle the starter pulley and spring cassette from the starter housing.
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1 Starter
Assembly (also see model Mondo)
Place a new spring cassette in position in the starter housing.
Replace the cord and attach as illustrated.
Assemble the starter pulley.
Assemble the starter handle (see model 265).
Tension the return spring.
Repeat tensioning the spring and fit the locking plates.
Models 140B, 141B
Dismantling
Remove the screws and lift off the starter.
Offload the spring tension and remove
the starter pulley from the starter housing.
Models 140B, 141B
Dismantling
Remove the 4 screws holding the starter
against the engine body.
Lift the starter cord out of the cut-out in
the starter pulley.
Offload the spring tension by allowing the
starter pulley to rotate backwards. Stop
the pulley using your thumb.
Remove the screw and washer from the
centre of the starter pulley.
22
Lift off the starter pulley.
Dismantle the return spring.
Clean and replace any damaged parts.
Carefully lift off the starter pulley and
return spring.
!
The return spring lies tensioned in the
starter housing and can fly out and cause
personal injury with careless handling.
Clean and replace any damaged parts.
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WARNING!
Wear protective glasses.
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Starter
Assembly
Fit a new return spring in the starter
housing.
Replace the starter cord and attach as
illustrated.
Wind the cord 4 turns clockwise around
the starter pulley.
Lubricate the spindle and return spring
and assemble the starter pulley.
1
Assembly
Fit a new return spring in the starter
housing. Exercise great care so that it
does not fly out.
WARNING!
!
Check that the spring’s mounting is facing the right way!
Attach a new starter cord in the starter
pulley as illustrated.
Wind the cord 4 turns clockwise around
the starter pulley.
Lubricate the spindle and return spring
with a few drops of oil.
Place the starter pulley in position and
tighten the screw in the centre. Do not
forget the washer.
Wear protective glasses.
Assemble the starter handle. Assemble the starter handle.
The collar on the washer should face
towards the starter handle.
Tension the return spring.
Check that the pulley can be turned a
further half turn with the starter cord fully
extended!
Tension the return spring.
● Pull out the cord approx. 30 cm and
stop the starter pulley using your
thumb.
● Lift the starter cord up in the cut-out in
the starter pulley.
● Wind the cord 2 turns anticlockwise
around the hub on the starter pulley.
● Pull out the starter cord fully.
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1 Starter
Models 140B, 141B
Drive dogs
Dismantle the drive from the crankshaft.
Replace the drive dogs if they are dam-
aged or worn.
Assembly, general
Assemble the starter following the reverse order set out for dismantling.
503 21 22-01
Models 140B, 141B
Drive dogs
Dismantle the drive dog from the crankshaft.
Unscrew the nut (anticlockwise) and then
unscrew the drive in the same direction.
Replace the drive dogs if they are damaged or worn.
Fit the new dog in the hole marked “R”.
Assembly, general
Assemble the starter.
Pull out the starter cord a little. Position
the starter. Release the starter cord and
ensure that the drive dogs grip in the
starter pulley.
Tighten the screws.
NOTE!
If the plastic threads in the crankcase have, for some reason,
been damaged it is recommended to use an over dimensioned screw (no 503 21 22-01).
Replacing the drive
dogs
See chapter 2. “Ignition system, flywheel”
with regard to engines that have the drive
dogs fitted on the flywheel.
Replacing the drive
dogs
See chapter 2. “Ignition system, flywheel”
with regard to engines that have the drive
dogs fitted on the flywheel.
24
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Ignition system
2.
Contents
Checking the spark________________________ 26
Replacing the spark plug cap ________________ 28
Dismantling ______________________________ 29
Dismantling the flywheel____________________ 33
Drive dogs_______________________________ 34
Assembly _______________________________ 36
Technical data ____________________________ 38
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2
Ignition system
The engine is equipped with an electronic ignition
system with no moving parts. Consequently, a faulty
component cannot be repaired, but must be replaced
with a new one.
Checking the spark
All models
Clean the electrodes and check the electrode gap.
The ignition spark in an electronic ignition system has a very short burn time and can be
judged to be weak and is at times difficult to see
when trouble shooting.
Checking the spark
All models
Remove the spark plug and clean off any
carbon deposits using a wire brush.
Check the electrode gap, it should be 0.5
mm.
Adjust the gap to the correct size using
the side electrode.
If the electrodes are worn by more than
50% the spark plug should be replaced.
Check whether there is a spark when
attempting to start, if not test using spark
plug no. 502 71 13-01.
If the electrodes are worn by more than
50% the spark plug should be replaced.
An excessive spark gap can overload the
ignition module and risk short circuiting.
Ensure the stop switch is in the 'start'
position.
Earth the spark plug against the cylinder
and pull the starter handle sharply.
There should now be a spark between the
electrodes.
If there is no spark try using the test spark
plug no. 502 71 13-01.
If there is spark now the spark plug is
faulty.
Fit a new spark plug.
26
502 71 13-01
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Ignition system
Fit a new spark plug.
If there is no spark disconnect the stop
switch.
Replace the switch if necessary.
Check the ignition lead's connections. Still no spark?
A
Fit a new spark plug.
If the procedure does not produce a spark
remove the short circuit cable from either
the ignition module or the stop switch.
If there is now a spark the stop switch is
faulty.
Replace the switch.
Check the spark plug connections.
Pull back the rubber covers by the spark
plug (A) and the ignition module (B) and
check that the ignition cable is not damaged. Cut off a piece of the cable to give
a good connection if required.
2
B
Lubricate the cable ends with grease. Lubricate the cable ends with a little
grease to facilitate assembly and to prevent dampness from entering the connections.
Check other cables and connections. Still no spark?
Check other cables and connections for
bad contact (dirt corrosion, cable breaks
and damaged insulation).
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Tip!
Use an ohmmeter to check whether there
is a broken cable caused by crushing, for
example.
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2
Ignition system
Check the air gap. Still no spark?
Check the air gap between the flywheel's
magnet and the ignition module. The gap
should be 0.3 mm.
Use air gap gauge 502 51 34-02.
Model 122 should have a 0.38 mm gap.
Use air gap gauge 531 00 48-61
502 51 34-02
Adjust the air gap.
531 00 48-61
Adjust the air gap to the right measurement.
● Loosen the screws.
● Insert the gauge and press the igni-
tion module against the flywheel.
● Tighten the screws and check the air
gap once again.
If there is still no spark the ignition system
should be replaced.
Model 122
Changing the spark plug
cover
1. Push the ignition cable through the
spark plug cover.
2. Make a hole in the ignition cable for
the contact spiral.
502 50 06-01
3. Fit the contact spiral on the ignition
cable.
Changing the spark plug
cover
1. Lubricate the ignition cable using a
little grease and push it through the
spark plug cover.
2. Cut off a piece of the ignition cable
(about 5 mm) and make a hole in the
cable for the contact spiral using the
pliers no. 502 50 06-01.
3. Fit the contact spiral on the ignition
cable, taking care to form the wire
along the cable.
4. Pull the contact spiral into the spark
plug cover.
NOTE!
It is important that the point of the
contact spiral is positioned so that
it's unable to pierce the spark plug
cover.
28
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Ignition system
Dismantling
General
Remove all components necessary to
gain access to the flywheel and ignition
module.
Models 322, 325
Dismantle the guard over the muffler.
Disconnect the throttle cable and remove
the screws holding the clutch cover.
Remove the clutch cover and loosen the
short-circuit cable from the ignition module.
2
Dismantling
General
Dismantle the cylinder cover, spark plug,
starter and air guide rail.
Models 322, 325
In addition to the components mentioned
above, you also need to dismantle the
guard over the muffler.
Disconnect the throttle cable from the
carburettor.
Remove the three screws holding the
clutch cover.
Remove the clutch cover complete with
the shaft from the engine.
Loosen both ends of the short-circuit cable from the ignition module.
504 90 00-02
B
A
B
A
B
Dismantle the ignition module and the
centrifugal clutch.
504 90 00-03
Model 122
Pull apart the connectors (A).
Remove the throttle cable at (B).
Remove the screws (C) and lift off the
shaft.
Remove the remaining screws (A) holding the ignition module and both screws
(B) that hold the centrifugal clutch.
Lift off the clutch and ignition module.
Model 122
Pull apart the connector on the electrical
cables (A) and remove the throttle cable
from the carburettor lever (B).
Remove the screws (C) and lift off the
shaft.
C
29
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