Husqvarna 165R Instruction manual

Technical data
Service data
Special tools
Fuel system, carburettor
Electrical system
Cylinder, piston
Crankcase, crankshaft
Starter
Handlebars, controls
Engine mounting, drive shaft
Transmission system

Ignition system
Ignition advance
Sparking plug
Sparking plug gap
Ca
r
bu
r
e
tt
o
r
Fuel tank capacity
Harness
Saw blade
Shaft angle
Weight
Grease
Classification table
SEM, type GA2
24° b t d c at 142 r/s (8500 r/mm)
Bosch WS7F, Champion CJ7Y
0.5mm
Tlllotson diaphragm carburettor type HS 121 A
Basic setting
H = 3/3 turn
L=1turn
1.0 litre petrol admixture
Fuel mixture 4% (1:25) oil
With Husqvarna Twostroke Oil 2% (1:50)
Husqvarna, type BU 75
Husqvarna, type Maxi 9“
110°
10.8kg
Empty clearing saw without harness and transit protection
for saw blade
EP 0 grease or Husqvarna special grease,
order number 502 51 27-01
Cylinder class Piston class
A A
B B
C C
If absolutely necessary,
a class A piston may be
used with a class B
cylinder.
NOTE:
A class B piston must not be used with a class A
cylinder nor a class C piston with a class
B cylinder
1
:
1

Leakage testing
Pressure: 0.08 MPa (0.8 kgf/cm2)
Max. leakage: 0.02 MPa per 30 see
(0.2 kgf/cm2 per 30 sec. )
Tools: 502 50 38-01 Pressure tester
502 50 45-01 Spacer sleeve (35 mm)
502 50 47-01 Sealing plate, inlet
502 50 48-01 Sealing plate, exhaust
Starter
It should be possible to turn the cord pulley about
another half-turn when the starter cord 15 fully with-
drawn.
Carburettor
Pressure: 0.03 MPa (0.3kgf/cm2, 4.3 psi)
Leakage: No leakage permitted
Tools: 502 50 38-01 Pressure tester
502 50 45-01 Spacer sleeve (35 mm)
502 50 47-01 Sealing plate, inlet
502 50 48-01 Sealing plate, exhaust
2:1

Fuel mixture
The engine is of two-stroke type and receives lubrica-
tion through the addition of oil to the petrol certain
proportions For ordinary two-stroke oil a mixture of 1
part oil to 25 parts petrol (4°/0) is recommended.
For premixed two-stroke oil a mixture of 1 part oil to 20
parts petrol (5%) is recommended.
For Husqvarna Two-stroke Oil a mixture of 1 part oil to
50 parts petrol (2%) is recommended.
The table below shows the different mixture proportions.
Mixture table
Litres For 2% For 4YO For SO
of petrol mixture mixture mixture
Litres of oil Litres of oil Litres of oil
5 0.1 0.2 0.25
10 0.2 0.4 0.50
15 0.3 0.6 0.75
20 0.4 0.8 1.00
25 0.5 1.0 1.25
2:2

2:3

502 50 06-01
Pliers, sparking
plug cover
502 50 18-01 NV 4 mm
502 50 18-01 NV 3 mm
502 50 64-01 NV 5 mm
T-type Allen key
502 50 20-01 (M5)
Stud tightener
502 50 22-01 NV 8 mm
502 50 23-01 NV 10 mm
Nut driver
502 50 25-01
Holdfast, complete
502 50 26-01
Puller, complete with screw
520 50 36-01
Tachometer
502 50 37-01
Vacuum tester, complete
502 50 38-01
Pressure tester, complete
502 50 42-01
Lithium grease, 250 g
502 50 45-01
Spacer sleeve, 35 mm
502 50 47-01
Sealing plate, inlet
502 50 48-01
Sealing plate, exhaust
502 50 49-01
Pliers, centrifugal
clutch
3:1

3:2
502 50 50-01
Repair kit for electric
leads
502 50 51-01
Crimping pliers
502 50 53-01
Sealing ring assembly
socket
502 50 63-01
Extractor, angle
gear
502 50 65-01 (M10)
Puller, gear shaft
502 50 70-01
Piston assembly kit,
complete
502 50 78-01
Extractor, sealing ring
502 50 79-01
Sealing ring assembly
sleeve
502 50 83-01
Hook for tank weight
502 50 86-01 NV 3 mm
502 50 87-01 NV 4 mm
502 50 88-01 NV 5 mm
Socket driver with ball
502 50 90-01
Jet-Pac spray gun, complete
with touch-up paint
502 50 91-01
Touch-up paint, orange
1/8 litre
502 50 92-01
Propellant gas for Jet-Pac
502 51 02-01
Assembly Jig
502 51 03-01
Special fixture

502 51 06-01
Glue
502 51 07-01
Epoxy adhesive
502 51 08-01
Loctite AA (normal
locking force)
502 51 09-01
Loctite AAV (high
locking force)
502 51 24-01
SEM ignition system tester
502 70 04-01 (M12)
Screw for puller
3:3

Dismantling the carburettor
Clamp the cleanse saw in fixture No 502 51 03-01.
Remove the cylinder casing and blow as much dirt as
possible away from the area round the carburettor,
using compressed air
Remove the sparking plug cover and air cleaner Do not
yet remove the plastic sleeve over the carburettor adju-
sting screws as this is held in place by a nail
Close the choke flap to prevent dirt from entering the
cylinder Disconnect the fuel line and back off the two
nuts (nut driver No 502 50 22-01) holding the carburet-
tor place.
Open the choke flap and pull the carburettor straight
out to the rear.
Remove the small nail holding the plastic sleeve in position
over the adjusting screws and remove the sleeve.
Clean the outside of the carburettor.
Back off the four screws holding the diaphragm cover in
place and remove the cover Remove the diaphragm
Note that the centre stud of the diaphragm enters a
fork-shaped opening in the needle valve lever
Connect pressure tester No 502 50 38-01 to the fuelinlet
on the carburettor and pump it up to a pressure of
0 03 MPa (0 3 kgf/cm2)
Check whether any leakage occurs at the needle valve
or at the gasket on the pump side Leakage points can
most easily be located by dripping petrol onto the places
where leakage is suspected.
Back off the screw holding the shaft on which the lever
pivots and remove lever, shaft, spring and needle valve
4:1

Drill a small hole (diameter approx 2 mm) in the two
blank plugs and pose the plugs out by means of a sharp
object
NOTE:
Exercise care whe n drilling to avoid damaging the
carburettor housing
Back off the two adjusting screws and remove the cover
over the pump diaphragm Remove the diaphragm and
gasket.
Carefully remove the fuel f filter from the carburettor hou-
sing using a sharp object
Checking the carburettor
A. Pump
Clean the fuel filter carefully using compressed air.
Clean all fuel passages and chambers using compres-
sed air
Inspect the pump diaphragm for signs of fatigue and da-
mage (holes).
4:2
B. Metering system
Check that the adjusting screws are straight and that no
tip is broken.
Inspect the cones for damage.
Inspect the diaphragm for wear in the centre stud slot
and for any signs of fatigue or other damage (holes)
Check that the gasket is undamaged.
Inspect the needle valve for wear at the tip and in the
groove for the lever Fig. 4:10 shows a worn needle valve
on the left and a new one on the right

The needle valve lever must not be worn either at the
needle valve end or the diaphragm end (see Fig 4:11)
Check that the filter screen at the main Jet is neither
dirty nor damaged
C. Mixture arrangements
Blow all fuel passages and lets clean with compressed
air
Make sure that the screws retaining the choke and
throttle flaps are tight
Check that the throttle flap shaft and its Journalling in
the carburettor housing are not so badly worn that air
might leak past
Fit replacements f any north are damaged or worn
Assembling the carburettor
A. Pump
Carefully fit the fuel filter back in place.
Check that it is the right way round with the flared collar
upwards.
Place the pump diaphragm on the carburettor housing
and then the gasket and cover.
Tighten the four cover screws alternately.
B. Metering system
Fit new blank plugs Press them into place by means of
suitable pin punches or the like:
for the large plug punch diameter 8 mm
for the small plug punch diameter 4 mm
NOTE:
Do not press down on the plugs with such force that they
bend inwards
In such event they may not seal as intended
Fit the needle valve lever with shaft and spring.
Make sure that the spring is mounted in the right position
HELPFUL HINT
The large set of spare parts for the carburettor carries
order number 501 54 67-01.
4:3

When correctly adjusted. the needle valve lever should
be on a level with the carburettor housing (see Fig.
4:14) The lever can be adjusted by bending the forked
end up or down (press the needle valve down at the
same time).
Check that the lever and needle valve can move freely
after adjustment Pressure-test the carburettor as de-
scribed above (see Fig. 4:5)
Then fit the gasket, diaphragm and cover back in place
NOTE:
The centre stud of the diaphragm should fit in the opening
in the lever.
Refit the adjusting screws and adjust them to the basic
setting:
High speed needle H = 3/4 turn open
Low speed needle L = 1 turn open
Fitting the carburettor to
the cylinder
If the studs holding the carburettor were unscrewed
from the cylinder when backing off the carburettor
nuts, screw the short thread into the cylinder again.
Check that the choke control in the open position.
Fit the plastic sleeve over the carburettor adjusting
screws and secure it in place with the small nail.
Set the choke flap in the open position.
Open the throttle flap fully by pressing on the lever with
your index finger.
Push the carburettor into position over the studs, mak-
ingng sure that the pin of the choke flap shaft correctly
enters the groove in the choke control. Tighten the nuts.
4:4
Connect the fuel line and check that it has no kinks that
may interrupt the supply of fuel.
Fit the air cleaner in place.
C
ar
b
ure
tt
or
t
un
i
ng
A. Basic setting
Before tuning the carburettor, proceed as follows:
Clean the air cleaner or fit a new one, if necessary
inspect the sparking plug and its electrodes.
Check that the fuel filter is not clogged.
After checking the above, turn the carburettor adjusting
screws to the basic setting:
H = 3/4 turn, L = 1 turn
Use screwdriver No 501 60 02-01
Start the clearing saw and warm it up by cutting into a
stump or the like.
Adjust idling speed by turning throttle stop screw T to a
position where the saw blade tends to rotate, i.e. a
comparatively high idling speed.

Carry out fine adjustment as follows:
1. Screw the L needle in slowly from the basic setting.
Engine speed will increase and then decrease when
the fuel-air mixture becomes too lean Note the needle
setting at which engine speed is highest.
2. Now unscrew the L needle and again note the setting
at which engine speed is highest. Note that the engine
will run slower when the fuel-air mixture is too rich
3. Turn the L needle to the position giving the highest
engine speed and then unscrew it by an amount cor-
responding to ten minutes on a clock face to give the
engine a slightly richer mixture.
4. Set the idling speed by means of throttle stop screw T to
2200-2300 r/min.
5. Open the throttle smartly a couple of times to check that
the engine responds.
If itdoes not unscrew the L needle by an amount cor-
responding toabout three minutes on a clock face.
Try again.
N
ow a
dj
us
t
th
e
H
nee
dl
e
t
o
th
e correc
t
se
tti
ng as
follows:
Run the engine at maximum speed by holding the throttle
control firmly open if the setting is correct the engine
should "four-stroke"
Reduce engine speed by slowly screwing in H needle
until fourstroking ceases From this position back it off
corresponding to ten minutes on a clock face
If a tachometer such as No 502 50 36 01 is available do not
allow the engine to race at more than 11200 r/min
Carburettor tuning is now flashed and the throttle control
can be released
NOTE
A carburettor that as set to gave too weak a mixture will
result in a considerable power loss Tune the carburettor
for maximum power and not for maximum speed
4:5

4:6

A. Fault tracing
A1 Dismantle the cylinder casing and remove the spar-
king plug. Reconnect the plug lead and rest the
sparking plug against ''earth'' e g the cylinder.
Check whether a spark occurs between the elec-
trodes when the engine is turned over by means of
the starter. The stop contact should be in position 1.
Try with a new sparking plug if there is sell no spark
then check that the connection between plug lead
and sparking plug cap is satisfactory.
A2 Disconnect the short-circuiting lead from the switch.
Turn the engine over and check whether a spark oc-
curs between the sparking plug electrodes. If it
does the stop contact is defective and should be re-
placed.
A3 If the ignition system is inoperative after carrying
out checks A1 and A2 dismantle the starter and guide
rail. It is not necessary to remove the tank filler cap.
Check that the short-circuitlng lead and plug lead are
not damaged.
A4 If no faults have been found in the previous checks,
the next step is to inspect the ignition coil.
Check the secondary winding of the ignition poll by
means of SEM ignition system tester No 502 51 24-01.
Connect the earth lead of the instrument to the
cylinder for example and the other lead to the plug
lead. The instrument should then give a reading
when set for resistance measurement.
A5. Remove the flywheel and ignition coil (see B. Dis-
mantling). Test the ignition coil under load.
Note that different makes of igolbon coil testers may
give different readings for the ignition coil. For this
reason we do not give any standard reading for the
coil but recommend the following test procedure:
Test three or four new ignition coils of the same type
as the one suspected of being defective. The avera-
ge reading obtained for these coils will then com-
prise a standard figure for the type of ignition coil
and tester in question Compare the reading for the
coil that may be defective with this standard figure.
If no test equipment is available we recommend re-
placement of the ignition coil after carrying out
checks A1-A4
Fig 5:4. SEM ignition system tester type G6/35E
A6. If no fault has been found in any of the previous checks
replace the electronic module or check it by means of
instrument No. 502 51 24-01.
5:1

Connect the module to the instrument as shown in
Fig. 5:5. Vary the position of the module on the
tester until a maximum reading is obtained on the
instrument. Compare this reading with the average
figure obtained when testing three or four new elec-
tronic modules.
B. Dismantling
Remove the starter and guide rail.
Back off the screws holding the securing plates for the
driver hooks and return springs (see Fig. 5:6) and remo-
ve these parts. Fit holdfast No 502 50 25-01 to the fly-
wheel and back off the nut, using a socket wrench (14
mm).
Fit puller No 502 50 26-01 to the holdfast and withdraw
the flywheel
NOTE:
Rest the flywheel on a clean surface to avoid metal
Sunny or metal objects hero attracted to the magnets.
Remove the sparking plug cap. Grasp the connecting
spring inside the cap with a pair of flat-nosed pliers (e.g.
50250 06-01) and withdraw spring and lead. A few drops
of oil applied to the inside of the cap will facilitate
reassembly.
Then unhook the spring from the lead.
Disconnect the short-circuiting leads from the contact.
Back off the screws retaining the armature plate.
Remove the armature plate and pull the leads together
with the rubber grommets out of the crankcase.
NOTE:
The protective sleeve on the short-circuiting lead contact
need not be removed.
C. Assembly
Flt the armature plate in reverse order to removal The
short-circuiting lead must be run under the carburettor

spacer. Exercise care on assembly to avoid damaging
the lead.
After flitting the armature plate n the crankcase it will
be necessary to set the timing, Rotate the plate until the
mark on the crankcase and the line inscribed on the ar-
mature plate are opposite each other (ignition system
SEM G6/35E see Fig. 510).
Tighten the screws securing the armature plate. Fit the
flywheel (note the key slot) and other components In re-
verse order to removal.
Use special pliers No 502 50 06-01 when fitting the
sparking plug cap to the plug lead to ensure satisfactory
connection between contact spring and lead.
We recommend applying grease No 502 50 42-01 to
both ends of the plug lead where it is connected to the
sparking plug cap and the ignition coil. In the latter case
the grease should be packed under the rubber cover.
5:3

Dismantling
Empty the fuel tank.
Clamp the clearing saw in fixture No 502 51 03-01.
Remove the cylinder casing and clean the cooling fins of
the cylinder as well as the area round the cylinder base.
Also clean the carburettor and spacer, making sure they
are free from metal filings and dirt.
Dismantle the following:
Starter, sparking plug cap sparking plug, air cleaner, fuel
hoe and carburettor.
Bend the ends of the securing plate aside and back off
the screws retaining the silence.r Note the two screws
securing the bottom of the silencer to the crankcase.
Remove the four screws securing the cylinder Use T-
type Allen key No 502 5018-01.
Carefully Oft the cylinder straight up.
Place a cloth in the crankcase opening to prevent dirt and
foreign objects from dropping into the crankcase Remove
the gudgeon pin retaining rings, using a pair of flat-nosed
pliers, and press the gudgeon pin out with a suitable pin
punch
Scrape the carbon deposits off the cylinder exhaust port and
combustion chamber
6:1

ins
p
ection
FAULT REMEDY
Broken cooling fins In serious cases - change the cylinder
Damaged threads Repair the threads with Heli-Coll inserts.
Binding marks in cylinder wall (particularly Clean the damaged area with One emery cloth to remove
at exhaust pod) adhering aluminium in the case of deeper binding scrat-
ches the cylinder and piston should be replaced
Surface coating on cylinder wail worn (chiefly at top Change cylinder and piston.
of cylinder)
Binding scratches on piston Clean the damaged area carefully with a fine file or emery
cloth. Clean the cylinder carefully as described above
before fitting the piston back in place. In the case of
deeper scratches the piston and possibly the cylinder
should be changed. Before assembly, clean both piston
and cylinder carefully to remove all metal bongs.
Piston ring burnt in as groove Carefully remove the piston ring and clean the groove
with extreme thoroughness before reassembly.
Piston ring worn Check the wear by positioning the ring i,7 the lowest pan
of the cylinder. The distance between the ends of the
piston ring should not exceed 0.6 mm. Also check that the
piston ring has lost none of its springiness.
A
ssem
bl
y
Check that the piston and cylinder are marked with the
same class designation (see Fig. 1:1 and the classifica-
tion table
Check that the gudgeon pin needle bearing is not dama-
ged or worn. Fit it in the connecting rod and lubricate
with a few drops of two-stroke oil.
Fit the piston to the connecting-rod.
NOTE: The arrow on the piston crown should point to-
ward the exhaust port.
they are correctly seated in their grooves by rotating
them with a pair of flat-nosed piers.
Lubricate the piston with a few drops of two-stroke off
Place the cylinder gasket in position on the crankcase.
Position the plastic support in assembly kit No. 502 50
70-01 under the piston.
6:2
Use a suitable drift to centre the piston opposite the
needle bearing in the connecting-rod. Slide the gudgeon
pin into position and fit the circlips in place. Check that