Husqvarna K 960 Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
K 960

1
1. LITERATURE 2
2. SPECIAL FUNCTIONAL COMPONENTS 3
3. COMPONENTS – ORIENTATION 4
4. DISMANTLING INTO BASIC MODULES 5
5. STARTER 9
6. IGNITION SYSTEM 12
7. FLYWHEEL 15
8. AIR FILTER 17
9. INLET SYSTEM 18
10. FUEL SYSTEM 20
11. CARBURETTOR 23
12. DECOMPRESSION VALVE 28
13. CYLINDER/PISTON 29
14. CRANKCASE 35
15. CLUTCH 40
16. CUTTING HEAD 44
17. FRICTION RETARDER 49
18. HANDLE 51
19. TOOLS 52
CONTENTS Page
HUSQVARNA
K 960
502 53 07-26

2
LITERATURE1
Workshop Manual
The Workshop Manual includes virtually
all workshop procedures that can come into
question on the K960. Some very simple and
self-evident repairs have been omitted.
Outline
An introductory section with the title
“Dismantling into Basic Modules” shows how
the machine is dismantled into large component
units, for example, the starter, cutting arm, air
filter, etc.
The manual goes on to describes in detail
through the different chapter how work on the
basic modules should be carried out.
This arrangement means that as a mechanic,
at least until you have learnt the basic composi-
tion of the machine, you need to start with the
chapter “Dismantling into Basic Modules” to
then move on to the chapter covering the speci-
fic service work.
Layout – pictures and text
Besides the pictures and illustrations there is
generally two columns of text. The left-hand text
column is a concise and is suitable for experienced
mechanics, the right-hand column gives a more
detailed description and is targeted at mechanics
with less experience of repair work on the power
cutter.
Contents
The manual is divided into numbered chapters
together with chapter headings that are stated in
bold at the top of each page.
The list of contents also has page references to
the start of each chapter.
Spare parts
Spare parts K960
The folder includes all the spare parts for
Husqvarna K960.
The folder contains complete exploded views
of the entire machine where each component's
placement, spare part number and appearance
can be easily identified.
HUSQVARNA CONSTRUCTION PRODUCTS
Workshop manual
K 960
“Dismantling into Basic Modules”
“Cutting head” (Example)
502 53 07-26

SPECIAL FUNCTIONAL COMPONENTS
3
New technical solutions
Husqvarna K960 is the first model in a new
generation of power cutters with a number of
new technical solutions:
New engine technology – Dual
Charge
The cylinder, piston and carburettor are
radically changed.
The carburettor's inlet duct (venturi) is
split in two halves. The upper venturi half (A)
supplies the cylinder with clean air while the
lower half (B) gives an over-rich fuel/air mix-
ture. By leading the fuel-air mixture and the
clean air in separate flushing channels into
the cylinder, the proportions of the air-fuel
mixture and clean air can be controlled so
that these vary in different phases of the
engine's work cycle.
Cleaner exhaust fumes and improved
performance
The amount of uncombusted hydrocarbons
(HC) is reduced by the Dual Charge techno-
logy to about half compared with a tradi-
tional design. The emission values are now
well below levels in the regulations from
EPAII.
The output is higher over the entire speed
range and the torque in the lower speed range
is now significantly higher.
Lower vibration levels
The fuel tank is integrated in the handle unit,
which means lower handle vibrations through
the greater weight. A redesigned vibration
dampening element gives lower vibration
levels, compared to the forerunner K950.
Poly-V belt
This type of belt has improved strength and
is more resilient against stretching than pre-
vious V-belts, which results in longer intervals
between adjustments. Friction losses are also
less.
Friction Retarder
A new front belt pulley is being introduced in
2007 with a braking mechanism that takes
effect at low speeds.
Torx – T27
Torx screws, with the dimensions T27, are
used virtually throughout to simplify the ser-
vice work.
Note that screws with both a flat and fluted
undersides are used.
2
Torx T27
AA
B
A
B

COMPONENTS – ORIENTATION3
4
Components
1. Cutting blade
2. Blade guard
3. Adjustable handle for the blade guard
4. Front handle
5. Air filter cover
6. Cylinder cover
7. Fuel tank
8. Starter handle
9. Starter
5
4
1
23
6
89
10
11
12
1314
17
18
19
15
7
16
21
20
10. Combination spanner
11. Belt adjustment screw
12. Lock screws for belt adjustment
13. Cutting arm/rear belt guard
14. Throttle control
15. Rear handle
16. Throttle trigger lock
17. Water valve with tool attachment
18. Water connector
19. Choke Lever
20. Start throttle lock
21. Stop switch

Basic modules
This chapter shows how the machine is
built up of basic modules, for example,
the starter, carburettor, air filter system,
etc.
The purpose is to illustrate how you
can easily and effectively dismantle and
assemble the machine in its basic modules.
Service work on a component level, for
example, replacing the starter cord, is
described in detail in respective chapters.
Cutting head
1. Loosen the screws on the cutting head.
2. Slacken off the belt tension using the
adjuster screw. Dismantle the screws on
the cutting head.
3. Dismantle the front belt cover by
sliding it forwards.
4. Loosen the hoses by the water valve.
Lift off the belt from the pulley and
remove the cutting head.
5. Loosen the two screws on the rear belt
guard.
(Tightening torque when assembling
6.6–8.1 lbf·ft/9–11 Nm.)
6. Remove the guard.
DISMANTLING INTO BASIC MODULES 4
5
Starter
1. Loosen the 4 screws on the guard.
2. Dismantle the starter.
12
12
34
56

DISMANTLING INTO BASIC MODULES
4
6
Air filter
1. Loosen both screws on the guard and
remove the guard.
2. Lift off the filter base.
3. Carefully lift up the paper filter so
that dust does not fall down into the
inlet bend.
Cylinder cover
1. Loosen the three screws on the
cylinder cover.
2. Lift off the cylinder cover.
Carburettor
1a. Dismantle the choke control by
turning it to the side and removing it
from its bracket.
1b. Removed the throttle rod from the
throttle and dismantle from the carbu-
rettor.
1c. Pull off the fuel hose from the carbu-
rettor.
2. Remove the first screw holding the
carburettor on the crankcase.
3. Now insert the Torx key through the
hole in the handle and loosen both
screws holding the carburettor on the
inlet manifold.
12
3
1
12
a
bc
5
2
4
3
4. Remove the screws at least 10 mm.
Pull the carburettor slightly backwards, it
can now be lifted upwards.
5. Remove the guide for the carburettor
setting from the machine.

DISMANTLING INTO BASIC MODULES 4
7
Air duct
Dismantle the entire air filter unit,
cylinder cover and starter.
Note how the cable to the stop switch
and the ignition lead are fitted in the air
duct.
Loosen the ignition lead from the
spark plug and release the cable from the
air duct.
Loosen the cable lug on the ignition
module and the stop switch. Remove the
air duct.
Inlet nozzle
There are two flywheel positions where
the screws become accessible. Dismantle
the screw and pull out the nozzle.
Inlet manifold
Dismantle the entire air filter unit,
cylinder cover, starter, air duct and car-
burettor.
The cylinder must be lifted slightly to
replace the inlet manifold between the
carburettor and cylinder. See the detailed
description on page 21.
Assembly
6. Pre-assemble the components as
illustrated. Slide the screws slightly past
the contact face.
7. Note the partition wall in the inlet
manifold. Note that the marking “UP”
must face upwards, if the partition wall
was loosened when dismantling the car-
burettor.
7
6
Muffler
Dismantle the cutting head, air filter and
cylinder cover.
The muffler is secured by three screws.
Dismantle these and remove the muffler.
Assembly
The insulated fibre gasket should lie
against the muffler.
The heat shield should lie closest to the
cylinder.

M5 M5
M6
M6
DISMANTLING INTO BASIC MODULES4
8
Vibration dampening
Several service procedures can be facilitated by splitting the machine at the
vibration dampening element. Perform the following before splitting:
– dismantle the air filter unit and cylinder cover
– dismantle the starter
– loosen the cable lug on the ignition module and the stop button and
remove the air duct
– pull off the water hose by the valve
– pull off the fuel hose from the carburettor
– dismantle the throttle rod and choke control.
The engine unit is attached to the handle unit at four points with the
vibration dampening element in the form of springs.
To gain access to the spring's inner screw, the diameter of the Torx key
must be max. 5 mm. The combination spanner fits.
Individual vibration dampers can be replaced on a complete machine as
described below in the section “Actions for replacing”.
Splitting the machine
Dismantle the outer screws on the vibra-
tion dampers:
1. Behind the machine's ground support
Actions for replacing: The machine must
be split as described above. Dismantle
the muffler too.
2. Below the flywheel
Actions for replacing: Dismantle the star-
ter.
3. The handle loop by the cylinder
Dismantle the inner screw in the cylinder.
Actions for replacing: Dismantle the
vibration damper first.
Open the snap lock on the hose holder
and push out the hose (the lowermost
picture). Assemble in the reverse order.
4. Below the carburettor space
Actions for replacing: Dismantle the
starter, filter and cylinder cover. Dis-
mantle the throttle rod and pull the fuel
hose from the carburettor. Dismantle the
outer screws for the vibration dampers
according to 2 and 3.
Lift up the engine body at the rear and
dismantle the vibration damper.
Coarse thread
MT6
1 2
3 4

STARTER 5
9
Replacing the starter cord
Dismantle the starter.
Eliminate the spring force from
the return spring
1. Pull out the starter cord approximately
12 in./30 cm. Hold the starter pulley
with your thumb and place the cord in
the cut-out on the starter pulley.
2. Let the starter pulley rotate slowly and
wind up the cord on the metal sleeve.
3. Lift off the cord from the starter
pulley.
Attach the new starter cord
The starter cord should be 45 in./
115 cm long and have a diameter of
.16 in./4 mm.
1. Insert one end of the cord from the
top through the hole in the starter pulley
and then out through the notch for the
cord. Pull out virtually the whole cord
length until sufficient cord remains to tie
a knot as illustrated.
2. Insert the other end through the cover
and on through the handle. Tie a double
knot as illustrated.
Loading the return spring
1. Fit the starter cord in the cut-out.
2. Wind the starter cord 4 turns around
the hub.
3. Pull out the starter handle so the cord
rolls off the hub.
4. Release so the cord is wound on the
starter pulley.
Repeat the procedure with 3 turns of
cord around the hub.
Important check!
Check that the return spring does not act
as an end stop by extending the cord
fully. In this position it should be possible
to turn the starter pulley a least a further
half turn before the spring stops the
movement.
1
1
23
2
1 2
3 4