Husqvarna 555 Instruction manual

Workshop Manual
English
555 560XP/XPG
562XP/XPG

English - 3
Workshop Manual
Husqvarna 555, 560XP, 560XPG, 562XP and
562XPG
Contents
Index ...................................................................... 4
Introduction and safety instructions .................. 6
Technical data...................................................... 10
Service tools ....................................................... 12
Service data ......................................................... 14
Safety equipment ................................................ 16
Repair instructions .............................................. 24
Carburettor .......................................................... 34
Troubleshooting................................................... 56
Contents
Husqarna A has a policy of continuous product deelopment and therefore reseres the right to modify
the design and appearance of products without prior notice.

4 - English
nde
Index
B
Bar bolt 54
Replacing the bar bolt 53
C
Carburettor 34
Assembly 38
Cleaning and inspection 38
esign 34
ismantling 36
unction 35
Pressure testing the carburettor 40
Centrifugal clutch 30
Assembly of centrifugal clutch 31
Cleaning and inspection 30
ismantling the centrifugal clutch 30
Chain brake 17
Assembling the chain brake 18
Cleaning and inspection 17
ismantling the chain brake 17
Chain catcher 20
Replacing the chain catcher 20
Crankshaft and crankcase 49
Assembling a complete crankshaft 54
ismantling the crankcase and crankshaft 49
F
Fuel system 44
Replacing the fuel lter 44
Replacing the fuel hose 44
I
Ignition module and flywheel 28
Assembling the ignition module and ywheel 29
Cleaning and inspection 28
ismantling the ignition module and ywheel 28
Intake system 32
Assembling the intake system 33
Cleaning and inspection 33
ismantling the intake system 32
Introduction and safety instructions 7
General 7
General nstructions 8
Modications 7
Numbering 7
Safety 7
Special nstructions 8
Structure 7
Target group 7
Tools 7
M
Muffler 19
Assembling the mufer 19
ismantling the mufer 19
O
Oil pump and screen 31
Assembling the oil pump and screen 32
Cleaning and inspection 31
ismantling the oil pump and screen 31
P
Piston and cylinder 45
Assembling the piston and cylinder 47
ismantling the piston and cylinder 45
aults and causes 47
Pressure testing the cylinder 48
S
Service data 14
Service tools 12
Starter 25, 26
Cleaning and inspection 25
Cleaning and inspection: 26
ismantling the starter 25
Replacing a broken or worn starter cord 26
Replacing a broken return spring 27
Starter assembly 27
Stop control 20
ismantling the stop control 20, 21
Stop function 21
Resistance test - stop function 21
Symbols
Symbols in the Workshop Manual 9
Symbols on the saw 9
T
Tank unit 42
Assembly 43
ismantling 42
Tank valve 42
Technical Data 10
Threads 54
Repairing damaged threads 54
Throttle control lock, throttle lock and spring 22
Assembling the throttle lockout, throttle control
and spring 23
Cleaning and inspection 22
ismantling the throttle control lock, throttle
control and spring 22
Troubleshooting 57
Troubleshooting methods 58

English - 5
nde
V
Vibration damping system 43
Assembly 43
Cleaning and inspection 43
ismantling 43

6 - English
ntroduction and safety instructions
2 Introduction and safety regulations
Contents
2.1 General ...........................................................................................................................7
2.2 Safety .............................................................................................................................7
2.3 Target group ...................................................................................................................7
2.4 Modications....................................................................................................................7
2.5 Tools ...............................................................................................................................7
2.6 Structure .........................................................................................................................7
2.7 Numbering ......................................................................................................................7
2.8 General instructions ........................................................................................................8
2.9 Special instructions .........................................................................................................8
2.10 Symbols on the saw .......................................................................................................9
2.11 Symbols in the Workshop Manual ..................................................................................9

English - 7
2 Introduction and safety instructions
ntroduction and safety instructions
2.1 General
This Workshop Manual describes in detail how
to be troubleshoot, repair and test the chain saw.
A description of different safety steps that must be
taken during repair work is also gien.
2.2 Safety
Note: The section dealing with safety must be
read and understood by all those carrying out
repair work or service on the chain saw.
Warning symbols can be found in this Workshop
Manual and on the chain saw. See Symbols on
the saw and Symbols in the Workshop Manual.
A new warning symbol decal must be applied as
soon as possible if a warning symbol on the chain
saw has been damaged or is missing so that the
greatest leel of safety can be maintained when
using the chain saw.
2.3 Target group
This Workshop Manual is written for personnel who
are assumed to hae general knowledge of repair-
ing and sericing chain saws.
The Workshop Manual must be read and under-
stood by personnel who will carry out repair work
and serice on the chain saw. The Manual is also
suitable for use when training new employees.
2.4 Modifications
Any modications to the chain saw will be gradually
introduced into ongoing production. As these modi-
cations affect serice and/or spare parts, specic
serice information will be sent out on each occa-
sion. This means that in time this Workshop Manu-
al will become out of date. n order to preent this,
the Manual should be read together with all serice
information concerning the chain saw in question.
2.5 Tools
Special tools are required for some stages. All
serice tools are listed in the Workshop Manual.
Usage is made apparent in each section.
Always use Husqvarna’s original:
• Spare parts
• Service tools
• Accessories
2.6 Structure
This Workshop Manual can be used in two different
ways:
 Repair of a specic system on the chain saw.

ismantling and assembly of the entire chain saw.
Repair of a specific system
When a particular system on the chain saw is to be
repaired, proceed as follows:
1. Look up the page for the system in question.
2. Carry out the following steps:
ismantling
Cleaning and inspection
Assembly
Dismantling and assembling the chain saw.
Proceed as follows when the chain saw is to be
dismantled and assembled:
1. pen the Repair instructions chapter which
deals with the Starter and carry out the in-
structions outlined under the Dismantling
heading.
2. Work forward in the Manual and carry out Dis-
mantling in the order set out in the sections.
3. Go back to the Starter and carry out the in-
structions under Cleaning and Inspection.
4. Work forward in the Manual and carry out
Cleaning and Inspection in the order set out
in the sections.
5. rder or collect all requisite spare parts from
the stores.
6. Look up the Repair instructions chapter which
deals with the Crankcase and carry out the
instructions outlined in Assembling.
7. Work back in the Manual and carry out Assem-
bling in the order set out in the sections.
Some sections include an introductory Descrip-
tion of the actual unit in order to increase the basic
understanding.
2.7 Numbering
Position references to components inside the g-
ures are designated A, , etc.
The gures are numbered 1, 2 etc.
The position references and gure numbers restart

8 - English
2.8 General Instructions
The workshop where the chain saw is to be re-
paired must be equipped with safety equipment in
accordance with local regulations.
No one may repair the chain saw unless they hae
read and understood the content of this Workshop
Manual.
This workshop manual contains the following warn-
ing boes in releant places.
2.9 Special Instructions
The fuel used in the chain saw has the following
haardous properties:
 The uid and its apour are poisonous.
 Can cause eye and skin irritation.
 Can cause breathing problems.
 s highly inammable.
When using compressed air, do not direct the et
towards your body. Air can penetrate into the blood
stream, which can endanger life.
Wear protectie earplugs or earmuffs when test
running.
After test running, do not touch the mufer until
it has cooled down. Risk of burns. Use protectie
gloes when working with the mufer.
o not start the chain saw unless the bar, chain
and clutch coer chain brake are tted, otherwise
the clutch may loosen and cause personal inury.
nsufcient chain lubrication can result in chain
breakage, which can cause serious or een life-
threatening inury.
Eercise care to ensure the starter spring does not
y out and cause personal inury. Wear protectie
glasses. f the spring tension is actiated on the
starter pulley when it is to be taken up, the spring
can y out and cause personal inury.
Check that the brake is applied when remoing the
pressure spring on the chain brake. therwise the
pressure spring can y out and cause personal
inury.
After repairing, check the chain brake, see Assem-
bling chain brake  unction check.
Keep in mind the re risk. The chain saw may emit
sparks, which cause ignition.
Check the chain catcher and replace it if it is dam-
aged.
WARNING!
The warning box warns of the risk
of personal injury if the instruc-
tions are not followed.
NOTE!
This box warns of material damage if the
instructions are not followed.
ntroduction and safety instructions

English - 9
ntroduction and safety instructions
2.10 Symbols on the saw
The symbols below are embedded on the chain
saw.
Choke Leer
Refuelling
Stop button
Chain oil ll.
Chain brake
ecompression ale
uel pump
Adusting the oil pump
2.11 Symbols in the Workshop Manual
This symbol warns of personal inury
when the instructions are not followed.

10 - English
isplacement Cylinder diameter Stroke length Ma. output/speed
cm3/cubic inch  mm/ inch mm/inch kW/hp/ rpm
555: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.1 / 4.2 / 9600
560XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9600
562XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9600
Electrode gap gnition system Air gap Carburettor type
mm/inch mm/inch
555: 0,5 / 0.02 SEM 0,3 / 0.012 ama
560XP/XPG: 0,5 / 0.02 SEM 0,3 / 0.012 ama
562XP/XPG: 0,5 / 0.02 SEM 0,3 / 0.012 ama
Usable cutting length Chain speed at Chain pitch rie link
cm/inch ma. output - speed mm/inch mm/inch
m/s - rpm
555: 33-61 / 13-24 21,3 / 9600 8.25 / 0.325 9,53 / 0.375 1.3 / 0.050 - 1,5 / 0.058
560XP/XPG: 33-61 / 13-24 21,3 / 9600 8,25 / 0.325 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058
562XP/XPG: 38-71 / 15-28 21,3 / 9600 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058
3 Technical data
Technical data

English - 11
Engage speed Spark plug Automatic oil pump
rpm
555: 3800 NGK CMR6H Yes
560XP/XPG: 3800 NGK CMR6H Yes
562XP/XPG: 3800 NGK CMR6H Yes
Volume fuel tank Capacity oil pump at Volume oil tank
Litre/US. pint 9,000 rpm, Litre/US. pint
ml/min
555: 0,65 / 1.37 6-15 0.33 / 0.70
560XP/XPG: 0,65 / 1,37 6-15 0,33 / 0.70
562XP/XPG: 0,65 / 1.37 8-18 0,35 / 0.74
Weight without bar and chain Weight with bar and chain
kg/lbs kg/lbs
555: 5,6 / 12.3 Weight depending on selected cutting equipment
560XP/XPG: 5,6 / 12.3
562XP/XPG: 5,7 / 12.6

GAS
OIL
Technical data

12 - English
6
10 11
4 Service tools
Serice tools
3 5
8
1 2
79
4 mm
5 mm
4
4 mm
12a
12b

English - 13
Serice tools
Pos escription Used for rder No.
1 Piston stop Locking the crankshaft 575 29 36-01
2 Hook for fuel lter Suspending the fuel lter 502 50 83-01
3 Allen key, 4 mm or M5 bolts 502 50 87-01
4 Allen key, 4 mm or M5 bolts 502 50 18-01
4 Allen key, 5 mm or M6 bolts 502 50 64-01
5 Air gap tool Setting, ignition module 502 51 34-02
6 Clutch tool Centrifugal clutch 575 25 14-01
7 Assembly ture Securing the chain saw 502 51 02-01
8 Pressure gauge Pressure testing 531 03 06-23
9 Test spark plug Checking the ignition module 501 97 64-01
10 Assembly pliers itting the spark plug guard 502 50 06-01
11 ismantling deice ismantling the crankcase 575 28 69-01
12a Assembly tool Assembling the sealring 575 34 70-01
12b Guide sleee Assembling the sealring 575 34 69-01
13a Coer plate, outlet Closure of outlet 574 71 14-01
13b Coer plate, inlet Closure of inlet 575 29 81-01
13c Coer plug, inlet Closure of inlet 574 70 12-01
13d Pressure tester Pressure testing the cylinder 503 84 40-03
14 Mandrel ismantling the ywheel 502 51 94-01
15 Assembly tool Assembling the crankshaft 502 50 30-23
16 Puller ismantling the crankshaft 531 00 48-67
17 Engine iagnostic Tool iagnosis and troubleshooting 576 69 23-01
14
13c
13b 16
17
13a13d
15

14 - English
5 Service data
Serice data
12-15 Nm 5mm
1,5-2Nm 4mm
5-6Nm 4mm
Min. 25Nm
1-2Nm
8-10Nm 4mm
4-5Nm 4mm
18-20Nm 16mm
12-15 Nm 5mm
Min. 15Nm 13mm
12-14Nm 13mm
1-2Nm
1-2Nm
1-2Nm
s  Lubricate using two-stroke oil.
n  Lubricate using chain oil.
l  Lubricate using grease.
The numbers by the components to be assembled with
screws state the tightening torque in Nm.
Key

English - 15
Serice data
3,5-4,5Nm 4mm
3,5-4,5Nm 4mm
4-5Nm 4mm
6-8Nm 4mm
7-9Nm 4mm
6-8Nm 4mm
22-25Nm 13mm
9-11Nm 4mm
3-4Nm 4mm
7-9Nm 4mm
3-4Nm 4mm
3-4Nm 4mm
2-3Nm 4mm
1-2Nm
3-4Nm 4mm
9-11Nm 4mm
8-10Nm 4mm

16 - English
6 Safety equipment
Safety equipment
Contents
6.1 ismantling the chain brake ...........................................................................................17
6.2 Assembling the chain brake ............................................................................................18
6.3 ismantling the mufer ...................................................................................................19
6.4 Assembling the mufer ...................................................................................................19
6.5 Replacing the chain catcher ...........................................................................................20
6.6 ismantling the start/stop control ...................................................................................20
6.7 Assembling the start/stop control ....................................................................................21
6.8 Resistance test - stop function .......................................................................................21
6.9 ismantling the throttle control lock, throttle control and spring .....................................22
6.10 Assembling the throttle control lock, throttle control and spring .....................................23

English - 17
3
Loosen the screws and insert a screwdrier to
maintain pressure on the spring, and then carefully
remoe the coer oer the brake spring, see g. 3.
WARNING!
Exercise care to ensure the spring
does not fly out and cause personal
injury. Wear protective goggles.
6.1 Dismantling the chain brake
2
Unscrew the kickback guard and remoe it.
NTE Make sure that the spring and rocker do not
y out.
Carefully tighten the clutch housing in a ice. Re-
lease the brake by using the saws hand guard as
a tool. Mesh with the brake and tighten anti-clock-
wise until the brake is actiated, see g. 2.
Cleaning and inspection
 Clean and check carefully all components. Parts
must be replaced if cracked or show signs of
other defects. Always use original spare parts.
• Measure the thickness of the chain brake band.
t must not be less than 0.6 mm in any place.
See gure 5.
 Lubricate the knee oint with grease.
4
Hold one hand on top of the brake spring and
press in a small screwdrier into the spring. Care-
fully bend upwards until the spring is released and
it slides onto the screwdrier, see g. 4.
Safety equipment
6 Safety equipment
1
Remoe the cylinder coer.
Release the brake by moing the front hand guard
backward.
Loosen the bar nuts and remoe the clutch coer,
bar and chain, see g. 1. ig 1
ig 2
ig 3
ig 4
ig 5
Alt. 1
Alt. 2

18 - English
6.2 Assembling the chain brake
1
Screw the knee oint and the brake band together
see gure 5 using a tightening torque of 1-1.5
Nm. Place the knee oint with the tted chain brake
band in the opening in the clutch coer. The space
for the spring in the coer must be lubricated with
grease. See gure 6.
2
Compress the spring with a wide screwdrier and
press it down with your thumb. See gure 7.
3
it the coer oer the brake spring using 1-1.5 Nm
tightening torque. See gure 8.
WARNING!
Exercise care to ensure the spring
does not fly out and cause personal
injury. Wear protective goggles.
4
Tighten the brake by using the saws hand guard
as a tool. Mesh with the brake and tighten clock-
wise until the brake is in the off position. See
gure 9.
5
NTE Make sure the bushings in the kickback
guards attachments are kept in place from the
inside. See gure 9.
Screw the kickback guard in place and put the
rocket in position. Position the spring  in the
plastic housing C see gure 10 and press the
spring against the rocker and then press the plastic
housing into its grooe. Tighten the chain guide
plate in place.
it the:
 bar
 chain
 clutch shoe
 cylinder coer
Safety equipment
ig 6
ig 7
ig 8
ig 9
A
B
C
ig 10

English - 19
NOTE!
After repairing, the chain brake must be in-
spected in line with the instruction below.
Functional inspection:
o not turn on the motor when carrying out this
inspection.
ar length Height
38 cm/15 50 cm/20
 Hold the chain saw oer a stable surface. The
distance between the bar and the surface is
shown in the table aboe.
 Let go of the front handle and let the chain saw
drop toward the surface underneath.
 When the bar hits the surface the chain brake
must trigger.
Safety equipment
WARNING!
Do not touch the muffler until it
has cooled. Risk of burns.
6.3 Dismantling the muffler
1
Remoe the cylinder coer, mufer, gasket and
cooling n.
2
The saw is tted with spark arrestor mesh, which is
remoed. f necessary, use the combination span-
ner to push down the plate edge and remoe the
spark arrestor mesh. See gure 12.
Cleaning and inspection
Clean and check all components carefully.
Parts must be replaced if cracked or show signs of
other defects. Always use original spare parts.
The spark arrestor mesh is best cleaned with a
wire brush.
The mesh must be replaced, if damaged.
The saw will oerheat if the mesh is clogged result-
ing in damage to the cylinder and piston.
Neer use a saw with a clogged or defectie mufer.
6.4 Assembling the muffler
1
f the saw is tted with a spark arrestor mesh, put
it in place rst. When tting the mesh, make sure
that the mesh is inserted in the right position. f
necessary, use the combination spanner to insert
the mesh.
2
it the:
 cooling n
 gasket
 mufer, tightening torque of 12-14 Nm.
 Cylinder coer
3
Warm up the saw for at least one minute and
retighten the screws on the mufer to 12 to 14 Nm.
ig 12
ig 11

20 - English
6.5 Replacing the chain catcher
A worn chain catcher must always be replaced with
a new one. Always use original spare parts.
1
Release the brake by moing the front hand guard
backward.
Loosen the bar nuts and remoe the clutch coer,
chain and bar.
2
Remoe the chain catcher and replace it with a
new one.
Make sure that the ibration element is tted cor-
rectly on the crankcase when a new chain catcher
is screwed in place. See gure 13.
Safety equipment
6.6 Dismantling the start/stop control
1
Remoe the cylinder coer and air lter. ismantle
the air lter holder. See the ismantling the carbu-
rettor chapter.
2
Loosen screw  and dismantle the stop control A.
See gure 14. Unhook the rubber collar around the
control from the guide plugs.
Cleaning and inspection
Clean and check carefully all components. Parts
must be replaced if cracked or show signs of other
defects. Always use original spare parts.
ig 13
ig 14