Husqvarna 560XPG Instruction manual

Workshop Manual
English
555 556 560XP/XPG
562XP/XPG

English - 2
Husqvarna 555, 556, 560XP,
560XPG, 562XP and 562XPG
Contents
Workshop Manual
1 Introduction and safety instructions .............. 3
1.1 General ......................................................................................................3
1.2 Safety..........................................................................................................3
1.3 Target group ............................................................................................3
1.4 Modications...........................................................................................3
1.5 Tools........................................................................................................... 3
1.6 Structure ...................................................................................................3
1.6.1 Repair of a specic system......................................................3
1.6.2 Dismantling and assembling the chain saw. ...................3
1.7 Numbering...............................................................................................3
1.8 General Instructions .............................................................................4
1.9 Special Instructions...............................................................................4
2 Symbols ............................................................ 5
2.1 Symbols on the saw..............................................................................5
2.2 Symbols in the Workshop Manual...................................................5
3 Technical data .................................................. 6
4 Service tools ..................................................... 8
5 Service data .................................................... 10
6 Safety equipment............................................ 12
6.1 Dismantling the chain brake ...........................................................12
6.2 Cleaning and inspection ...................................................................12
6.3 Assembling the chain brake ............................................................13
6.3.1 Functional inspection: ...........................................................14
6.4 Dismantling the muer....................................................................14
6.5 Cleaning and inspection ...................................................................14
6.6 Assembling the muer.....................................................................14
6.7 Replacing the chain catcher ............................................................15
6.8 Dismantling the start/stop control................................................15
6.9 Cleaning and inspection ...................................................................15
6.10 Assembling the start/stop control..............................................16
6.10.1 Resistance test - stop function .........................................16
6.11 Dismantling the throttle control lock, throttle control and spring...17
6.12 Cleaning and inspection.................................................................17
6.13 Assembling the throttle control lock, throttle control and spring...18
7 Repair instructions......................................... 19
7.1 Dismantling the starter......................................................................19
7.2 Cleaning and inspection ...................................................................19
7.3 Replacing a broken or worn starter cord ....................................20
7.4 Cleaning and inspection: ..................................................................20
7.5 Tensioning the return spring...........................................................20
7.6 Replacing a broken return spring..................................................21
7.7 Starter assembly...................................................................................21
7.8 Dismantling the ignition module and ywheel........................22
7.9 Cleaning and inspection ...................................................................22
7.10 Assembling the ignition module and ywheel......................23
7.12 Dismantling the centrifugal clutch.............................................24
7.11 Cleaning and inspection.................................................................24
7.13 Assembly of centrifugal clutch.....................................................25
7.14 Dismantling the oil pump and screen .......................................25
7.15 Cleaning and inspection.................................................................25
7.16 Assembling the oil pump and screen........................................26
7.17 Dismantling the intake system.....................................................26
7.19 Cleaning and inspection.................................................................28
7.18 Assembling the intake system......................................................28
7.20 Carburettor..........................................................................................29
7.20.1 Description ..............................................................................29
7.20.2 Design .......................................................................................29
7.20.3 Function....................................................................................30
7.21 Dismantling the carburettor .........................................................31
7.22 Cleaning and inspection.................................................................33
7.23 Assembly ..............................................................................................33
7.24 Adjustment of AutoTune at change of carburettor ..............35
7.25 Pressure testing the carburettor..................................................35
7.26 Fitting on the saw..............................................................................36
7.27 Tank unit ...............................................................................................38
7.28 Dismantling.........................................................................................38
7.29 Venting the fuel tank........................................................................38
7.30 Assembly .............................................................................................39
7.31 Vibration damping system.............................................................39
7.32 Dismantling.........................................................................................39
7.33 Cleaning and inspection.................................................................39
7.34 Assembly ..............................................................................................39
7.37 Replacing the fuel lter...................................................................40
7.35 Replacing the fuel hose/return hose..........................................40
7.36 Replacing the fuel pump (Purge) ................................................40
7.36.1 Dismantle.................................................................................40
7.36.2 Assembling..............................................................................40
7.38 Handle heater and carburettor heater (560XPG, 562XPG) 41
7.39 Troubleshooting ................................................................................41
7.40.2 Troubleshooting the heating element, rear handle .43
7.40.1 Troubleshooting the heating element, front handle43
7.39.1 Troubleshooting the generator........................................43
7.41 Replacing the front handle............................................................44
7.39.2 Troubleshooting the carburettor’s heating element
and thermostat ...................................................................................44
7.40 Replacing the heating element in the rear handle...............44
7.42 Replacing the generator.................................................................45
7.43 Replacing the carburettor’s heating element and thermostat...46
7.44 Dismantling the piston and cylinder..........................................48
7.45 Cleaning and inspection of the cylinder...................................48
7.46 Assembling the piston and cylinder...........................................50
7.47 Pressure testing the cylinder.........................................................51
7.48 Dismantling the crankshaft and crankcase .............................52
7.48.1 Dismantling of crankshaft bearings. ..............................53
7.48.2 Cleaning and inspection.....................................................53
7.48.3 Assembly of crankshaft bearings ....................................54
7.49 Assembly of crankshaft and crankcase .....................................54
7.50 Assembly of sealing rings...............................................................55
7.51 Assembling..........................................................................................56
7.52 Replacing the bar bolt.....................................................................56
7.52.1 Replacing a bar bolt with intact crankcase..................56
7.53 Repairing damaged threads ........................................................57
8 Troubleshooting.............................................. 58
8.1 Troubleshooting methods................................................................59

English - 3
1 Introduction and safety instructions
Introduction and safety instructions
1.1 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 given.
1.2 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
level of safety can be maintained when using the
chain saw.
1.3 Target group
This Workshop Manual is written for personnel who
are assumed to have general knowledge of
repairing and servicing chain saws.
The Workshop Manual must be read and
understood by personnel who will carry out repair
work and service on the chain saw.The Manual is
also suitable for use when training new employees.
1.4 Modifications
Any modifications to the chain saw will be gradually
introduced into ongoing production. As these
modifications affect service and/or spare parts,
specific service information will be sent out on each
occasion.This means that in time this Workshop
Manual will become out of date. In order to prevent
this, the Manual should be read together with all
service information concerning the chain saw in
question.
1.5 Tools
Special tools are required for some stages. All
service tools are listed in the Workshop Manual.
Usage is made apparent in each section.
Always use Husqvarna’s original:
• Spare parts
• Service tools
• Accessories
1.6 Structure
This Workshop Manual can be used in two different
ways:
• Repair of a specific system on the chain saw.
• Dismantling and assembly of the entire chain saw.
1.6.1 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:
Dismantling
Cleaning and inspection
Assembly
1.6.2 Dismantling and assembling the chain saw.
Proceed as follows when the chain saw is to be
dismantled and assembled:
1. Open the “Repair instructions” chapter which
deals with the Starter and carry out the
instructions outlined under the Dismantling
heading.
2. Work forward in the Manual and carry out
Dismantling in the order set out in the sections.
3. Go back to the Starter and carry out the
instructions 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. Order 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
Assembling in the order set out in the sections.
Some sections include an introductory Description
of the actual unit in order to increase the basic
understanding.
1.7 Numbering
Position references to components inside the
figures are designated A, B, etc.
The figures are numbered 1, 2 etc.
The position references and figure numbers restart
in each new section.

4- English
1.8 General Instructions
The workshop where the chain saw is to be repaired
must be equipped with safety equipment in
accordance with local regulations.
No one may repair the chain saw unless they have
read and understood the content of this Workshop
Manual.
This workshop manual contains the following
warning boxes in relevant places.
1.9 Special Instructions
The fuel used in the chain saw has the following
hazardous properties:
• The fluid and its vapour are poisonous.
• Can cause eye and skin irritation.
• Can cause breathing problems.
• Is highly inflammable.
When using compressed air, do not direct the jet
towards your body. Air can penetrate into the blood
stream, which can endanger life.
Wear protective earplugs or earmuffs when test
running.
After test running, do not touch the muffler until it
has cooled down. Risk of burns. Use protective
gloves when working with the muffler.
Do not start the chain saw unless the bar, chain and
clutch cover (chain brake) are fitted, otherwise the
clutch may loosen and cause personal injury.
Insufficient chain lubrication can result in chain
breakage, which can cause serious or even life-
threatening injury.
Exercise care to ensure the starter spring does not
fly out and cause personal injury. Wear protective
glasses. If the spring tension is activated on the
starter pulley when it is to be taken up, the spring
can fly out and cause personal injury.
Check that the brake is applied when removing the
pressure spring on the chain brake. Otherwise the
pressure spring can fly out and cause personal
injury.
After repairing, check the chain brake, see
“Assembling chain brake \ Function check”.
Keep in mind the fire risk. The chain saw may emit
sparks, which cause ignition.
Check the chain catcher and replace it if it is
damaged.
WARNING!
The warning box warns of the risk of
personal injury if the instructions are
not followed.
NOTE!
This box warns of material damage if the
instructions are not followed.
Introduction and safety instructions

English - 5
Introduction and safety instructions
2.1 Symbols on the saw
The symbols below are embedded on the chain saw.
Choke Lever
Refuelling
Stop button
Chain oil fill.
Chain brake
Decompression valve
Fuel pump
Adjusting the oil pump
2.2 Symbols in the Workshop Manual
This symbol warns of personal injury
when the instructions are not followed.
Use protective gloves.
Use protective goggles.
2 Symbols

6- English
Displacement Cylinder diameter Stroke length Max. output/speed
cm3/cubic inch Ø mm/Ø inch mm/inch kW/hp/ rpm
555: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.1 / 4.2 / 9 600
556: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.1 / 4.2 / 9 600
560XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9 600
562XP/XPG: 59,8 / 3.65 46 / 1.81 36 / 1.42 3.5 / 4.8 / 9 600
Electrode gap Ignition system Air gap
mm/inch mm/inch
555: 0,5 / 0.02 SEM DM61 0,3 / 0.012
556: 0,5 / 0.02 SEM DM61 0,3 / 0.012
560XP/XPG: 0,5 / 0.02 SEM DM61 0,3 / 0.012
562XP/XPG: 0,5 / 0.02 SEM DM61 0,3 / 0.012
Usable cutting length Chain speed at 133% of Chain pitch Drive link
cm/inch max. engine power speed mm/inch mm/inch
ft/s / m/s
555: 33-61 / 13-24 92.8 / 28,3 8.25 / 0.325 9,53 / 0.375 1.3 / 0.050 - 1,5 / 0.058
556: 38-71 / 15-28 92.8 / 28,3 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058
560XP/XPG: 33-61 / 13-24 92.8 / 28,3 8,25 / 0.325 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058
562XP/XPG: 38-71 / 15-28 92.8 / 28,3 9,53 / 0.375 1,3 / 0.050 - 1,5 / 0.058
3 Technical data
Technical data

English - 7
Engage speed Spark plug Automatic oil pump
rpm
555: 4 300 NGK CMR6H Yes
556: 4 300 NGK CMR6H Yes
560XP/XPG: 4 300 NGK CMR6H Yes
562XP/XPG: 4 300 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
556: 0,65 / 1.37 6-15 0,35 / 0.74
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 Heated handles Electrical carburettor
kg/lbs
555: 5,7 / 12.5 - -
556: 5,9 / 13.0 - -
560XP: 5,7 / 12.5 - -
560 XPG: 5,9 / 13.0 Yes Yes
562 XP: 5,9 / 13.0 - -
562 XPG: 6,1 / 13.5 Yes Yes
OIL
Technical data

8- English
6a
10 11
4 Service tools
Service tools
35
8
1 2
79
4 mm
5 mm
4
4 mm
12a
12b
6b

English - 9
Pos Description Used for Order No.
1Piston stop Locking the crankshaft 575 29 36-01
2Hook for fuel filter Suspending the fuel filter 502 50 83-01
3Allen key, 4 mm For M5 bolts 502 50 87-01
4Allen key, 4 mm For M5 bolts 502 50 18-01
4Allen key, 5 mm For M6 bolts 502 50 64-01
5Air gap tool Setting, ignition module 502 51 34-02
6a Clutch tool Centrifugal clutch (previous clutch) 575 25 14-01
6b Clutch tool Centrifugal clutch (current clutch) 582 83 42-01
7Assembly fixture Securing the chain saw 502 51 02-01
8Pressure gauge Pressure testing 531 03 06-23
9Test spark plug Checking the ignition module 501 97 64-01
10 Assembly pliers Fitting the spark plug guard 502 50 06-01
11 Dismantling device Dismantling the crankcase 575 28 69-01
12a Assembly tool Assembling the sealring 575 34 70-01
12b Guide sleeve Assembling the sealring 575 34 69-01
13a Cover plate, inlet Closure of inlet 574 71 14-01
13b Cover plate, outlet Closure of outlet 575 29 81-01
13c Cover plug, inlet Closure of inlet 574 70 12-01
13d Pressure tester Pressure testing the cylinder 503 84 40-03
14 Mandrel Dismantling the flywheel 502 51 94-01
15 Assembly tool Assembling the crankshaft 502 50 30-23
16 Puller Dismantling the crankshaft 531 00 48-67
17 Engine Diagnostic Tool Diagnosis and troubleshooting 576 69 23-01
18 Silicone tube Assembling piston and cylinder 503 26 72-01
Service tools
14
13c
13b 16
17
13a13d
15 18

10 - English
14-16Nm 5mm
1,5-2Nm 4mm
5-6Nm 4mm
25Nm
1-2Nm
8-10Nm 4mm
4-5Nm 4mm
18-20Nm 16mm
16-20Nm 5mm
11-13Nm 13mm
12-14Nm 13mm
1-2Nm
1-3Nm
1-2Nm
Previous style clutch, 574 23 61-04 Current style clutch, 587 89 92-01
25Nm
5 Service data
Service data
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 - 11
Service data
5-6Nm 4m
m
3,5-4Nm 4mm
5-6Nm 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
3-4Nm 4mm

English - 12
4. Carefully tighten the clutch housing in a vice.
Release the brake by using the saw’s hand
guard as a tool. Mesh with the brake and
tighten anti-clockwise until the brake is
activated, see fig. 2.
WARNING!
Exercise care to ensure the spring
does not fly out and cause personal
injury.Wear protective goggles.
3. Loosen the bar nuts and remove the clutch
cover, bar and chain, see fig. 1.
Unscrew the kickback guard and remove it.
NOTE! Make sure that the spring and rocker do
not fly out.
5. Loosen the screws and insert a screwdriver to
maintain pressure on the spring, and then
carefully remove the cover over the brake
spring, see fig. 3.
6. Hold one hand on top of the brake spring and
press in a small screwdriver into the spring.
Carefully bend upwards until the spring is
released and it slides onto the screwdriver, see
fig. 4.
6.2 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. It
must not be less than 0.6 mm in any place. See
figure 5.
• Lubricate the knee joint with grease.
Safety equipment
6 Safety equipment
6.1 Dismantling the chain brake
1. Remove the cylinder cover.
2. Release the brake by moving the front hand
guard backward.
Fig 1
Fig 2
Fig 3
Fig 4
Fig 5
Alt. 1
Alt. 2

13 - English
6.3 Assembling the chain brake
1. Screw the knee joint and the brake band
together (see figure 5) using a tightening torque
of 1-2 Nm. Place the knee joint with the fitted
chain brake band in the opening in the clutch
cover.The space for the spring in the cover
must be lubricated with grease. See figure 6.
2. Compress the spring with a wide screwdriver
and press it down with your thumb. See figure 7.
3. Fit the cover over the brake spring using 1-2
Nm tightening torque. See figure 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 clockwise until the brake is in the off
position. See figure 9.
NOTE! Make sure the bushings in the kickback
guard’s attachments are kept in place from the
inside. See figure 9.
5. Screw the kickback guard in place and put the
rocket in position. Position the spring (B) in the
plastic housing (C) (see figure 10) and press
the spring against the rocker and then press the
plastic housing into its groove.Tighten the
chain guide plate in place.
6. Fit the:
• bar
• chain
• clutch shoe
• cylinder cover
Safety equipment
Fig 6
Fig 7
Fig 8
Fig 9
A
B
C
Fig 10

English - 14
NOTE!
After repairing, the chain brake must be
inspected in line with the instruction below.
6.3.1 Functional inspection:
Do not turn on the motor when carrying out this
inspection.
Bar length Height
15-20” 50 cm
• Hold the chain saw over a stable surface.The
distance between the bar and the surface is
shown in the table above.
• 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
6.4 Dismantling the muffler
1. Remove the cylinder cover, muffler, gasket and
cooling fin.
2. If the carburettor is fitted with spark arrestor
mesh, this is removed. If necessary, use the
combination spanner to push down the plate
edge and remove the spark arrestor mesh. See
figure 12.
6.5 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 overheat if the mesh is
clogged resulting in damage to the cylinder and
piston.
• Never use a saw with a clogged or defective
muffler.
6.6 Assembling the muffler
If the carburettor is fitted with a spark arrestor mesh,
put it in place first. When fitting the mesh, make sure
that the mesh is inserted in the right position. If
necessary, use the combination spanner to insert the
mesh.
Fit the:
• cooling fin
• gasket
• muffler(cylinder screw), tightening torque of 19 Nm.
• muffler (crankcase screw), tightening torque of
14-16 Nm.
• Cylinder cover
3. Warm up the saw for at least one minute and
retighten the mufflers cylinder screws to 17 Nm.
WARNING!
Do not touch the muffler until it has
cooled. Risk of burns.
Fig 12
Fig 11
21-28” 70 cm

15 - English
6.7 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 moving the front hand
guard backward.
2. Loosen the bar nuts and remove the clutch
cover, chain and bar.
3. Remove the chain catcher and replace it with a
new one.
4. Make sure that the vibration element is fitted
correctly on the crankcase when a new chain
catcher is screwed in place. See figure 13.
Safety equipment
6.8 Dismantling the start/stop control
1. Remove the cylinder cover and air filter.
Dismantle the air filter holder. See the
“Dismantling the carburettor” chapter.
2. Loosen screw B and dismantle the stop control
A. See figure 14. Unhook the rubber collar
around the control from the guide plugs.
6.9 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.
Fig 13
Fig 14

English - 16
Safety equipment
“Dismantling the ignition module and flywheel”.
5. Cut open the shrink tube covering both cables
and shrink tubing that encloses the cable ends.
6. Clean the contact areas and check resistance
in the following way;
7. Test the resistance by connecting a multimeter
to the cable ends.
8. The stop switch is in the “on” position when the
button is held down (see figure 17) and in the
“off” position when the button is in neutral.
9. Resistance can be 0.5 Ohm at most with the
power switch in the “on” position.
10. When assembling (see figure 18), pull the cable
ends apart and slide on a thicker shrink tube
over both cables.Then slide on the thinner
shrink tubes over each cable. Connect the
cable ends together. Slide the thinner shrink
tubes over the cable ends and heat the shrink
tube first on both cables separately. Slide the
thicker shrink tube over the thinner shrink tubes
and then heat the thicker shrink tube.
6.10 Assembling the start/stop control
1. Fit the new stop control (A) and tighten screw
(B) in place at a torque of 1 Nm. Slide in the
stop control in the rubber sleeve C and hook
the sleeve on the guide taps. See figure 15.
Fig 15
Fig 16
2. Attach the cables as outlined in figure 16.
3. Attach the air filter holder. See the “Assembling
the carburettor” chapter.
4. Fit air filter and cylinder cover.
6.10.1 Resistance test - stop function
Dismantle the ignition module as outlined in
Fig 18
Fig 17
NOTE!
The power switch must be in the “on” position
to get the correct reading. See figure 17.

17 - English
Safety equipment
3. Press out the throttle control pin (C) with the
help of a punch. See figure 21.
4. Loosen the throttle cable (D) and lift out the
throttle control and the spring. See figure 22.
6.11 Dismantling the throttle control
lock, throttle control and spring
1. Loosen the screw on the rear handle. Remove
the handle insert (A). See figure 19.
6.12 Cleaning and inspection
• Carefully clean and check all parts. See figure 13.
Parts must be replaced if cracked or show signs
of other defects. Always use original spare parts.
• Check that the spring is intact and retains all its
tension.
Fig 20
Fig 21
Fig 22
Fig 23
Fig 19
A
2. Loosen the throttle control lock (B) as shown in
the figure using a screwdriver or similar tool.
Remove it then from the shaft in the handle.
See figure 20.

English - 18
6.13 Assembling the throttle control
lock, throttle control and spring
1. Lubricate the pin and joined surfaces with a
light oil. Hook on the throttle cable (D). Slide in
the throttle control and make sure the spring is
fitted as outlined in figure 24.
NOTE! Make sure that the rear end of the
throttle control is correctly aligned inside the
cut-out edging before the pin is pressed in
place.2
Safety equipment
Fig 24
Fig 25
Fig 26
C
2. Fit the throttle control’s pin (C) using a punch.
See figure 25.
3. Fit the throttle control lock (B) by sliding it on
the shaft in the handle. See figure 26. Make
sure the spring is positioned inside the throttle
control lock when you press it down so that the
barbs are hooked in place.
4. Fit the handle insert using a screw, when the
throttle control, spring, throttle cable and
throttle control lock with pin are fitted correctly.

English - 19
Repair Instructions
WARNING!
If the spring tension is activated on
the starter pulley, the spring can fly
out and cause personal injury. Wear
protective glasses.
7.1 Dismantling the starter
1. Loosen the four screws, which hold the starter
against the crankcase and remove the starter.
3. Loosen the screw in the centre of the pulley and
remove the pulley. See figure 3a. Loosen the
screws on the cassette and remove the
cassette and spring.
7.2 Cleaning and inspection
Clean the parts and check:
• The starter cord.
• That the starter pawls on the flywheel are intact,
i.e. that they spring back to the centre and move
easily.
• To lubricate the return spring using light oil.
7 Repair instructions
2. Pull the cord out about 30 cm and lift it into the
notch on the outside of the starter pulley.
Release the tension in the return spring by
letting the starter pulley rotate anti-clockwise.
See figures 1 and 2.
Fig 1
Fig 2
Fig 3a

20 - English
Repair instructions
7.3 Replacing a broken or worn starter
cord
When the starter cord is worn and must be replaced,
the tension in the return spring must be released.
1. Pull the cord out about 30 cm and lift it into the
notch on the outside of the starter pulley.
Release the tension on the return spring by
allowing the starter pulley to rotate slowly
backwards. See figure 3b.
7.5 Tensioning the return spring
1. Pull the starter cord up into the notch in the
starter pulley and turn the pulley about 3 turns
clockwise. Check that the pulley can be turned
at least a further 1/2 turn when the starter cord
is pulled all the way out. See figure 4.
2. Stretch the line with the handle. Remove your
thumb and let the cord spin back. See figure 5.
2. Loosen the screw in the centre of the pulley and
remove the pulley. See figure 3a.
3. When the starter pulley is removed, insert a
new starter cord and attach it to the starter
pulley. Thread the other end of the starter cord
through the hole in the starter housing and
starter handle and tie a double knot on the cord.
Wind approx. 3 turns of the starter cord on the
starter pulley.Turn the starter pulley until it
latches into the correct position.Tighten the
screw at the centre of the starter pulley, at a
tightening torque of 2-3 Nm.
7.4 Cleaning and inspection:
• Clean and check carefully all components. Worn
or damaged parts must be replaced. Lubricate
the return spring with a light oil.
WARNING!
If the spring tension is activated on the
starter pulley, the spring can fly out and
cause personal injury.
Wear protective glasses.
Fig 4
Fig 5
Fig 3b