Husqvarna 165R Instruction manual

Workshop manual
Clearing Saw
Model
101 88 04-26
165R
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RContents
Technicaldata
Servicedata
Specialtools
Fuelsystem,carburetor
Electricalsystem
Cylinder,piston
Crankcase,crankshaft
Starter
Handlebars,controls
Enginemounting,driveshaft
Transmissionsystem
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RTechnicaldata o
Ignitionsystem
Ignitionadvance
Sparkingplug
Sparkingpluggap
Carburetor
Fueltank capacity
Harness
Saw blade
Shaftangle
Weight
Grease
Classificationtable
SEM,type GA2
24° b.t.d.c. at 142 r/s (8500 r/rein)
Bosch WS7F, Champion CJ7Y
0.5 mm
Tillotson diaphragm carburetor type HS 121A
Basic setting:
H=3/3 turn
L=1turn
1,0Iitre petroil admixture
Fuel mixture 40/.(1:25) oil
With Husqvarna Twostroke Oil 2%(1:50)
Husqvarna, type BU 75
Husqvarna, type Maxi 9“
110°
10.8 kg
Empty clearing saw without harness and transit protection
for saw blade
EPOgrease or Husqvarna special grease,
order number 5025127-01
Cylinderclass Pistonclass
AA
BB
cc
If absolutely necessary,
aclass Apiston may be
used with aclass B
cylinder.
Fig. 1:1
NOTE:
Aclass Bpiston must not be used with aclass A
cylinder nor aclass Cpiston with aclass Bcylinder.
1:1
——
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RServiceData u
Leakagetesting
Pressure: 0.08 MPa (0.8 kgf/cmz)
Max. leakage: 0.02 MPa per 30 sec.
(0.2 kgf/cmz per 30 sec.)
Tools: 5025038-01 Pressure tester
5025045-01 Spacer sleeve (35 mm)
5025047-01 Sealing plate, inlet
5025048-01 Sealing plate, exhaust
Fig 2:1
Starter
It should be possible to turn the cord pulley about
another half-turn when the starter cord is fully with-
drawn.
Fig 2:2
Carburetor
Pressure: 0.03 MPa (0.3 kgf/cmz, 4.3 psi)
Leakage: No leakage permitted.
Tools: 5025038-01 Pressure tester
5025045-01 Spacer sleeve (35 mm)
5025047-01 Sealing plate, inlet
5025048-01 Sealing plate, exhaust
Fig 2:3
2:1
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

ServiceData !2
Fuelmixture
The engine is of two-stroke type and receives lubrica-
tion through the addition of oil to the petrol in certain
proportions. For ordinary two-stroke oil amixture of 1
part Oil to 25 pWLS petrol (4’’/.) krecommended.
For premixed two-stroke oil amixture of 1part oil to 20
PWk PdrOi (5Yo)krecommended.
For Husqvarna Two-stroke Oil amixture of 1part oil to
50 parts petrol (2Yo) is recommended.
The table below shows the different mixture proportions.
Mixture table
Litres For 2Y0 For hyo For 5Y0
of petrol mixture mixture mixture
Litres of Litres of Litres of
oil oil oil
50.1 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
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RServiceData Q
Tighteningtorques(Nm)
Lubricationpoints
II II II
aclo
2:3
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RSpecialtools w
&5025006-01
Pliers, sparking
plug cover
o./
P
149 5025018-01 NV 4mm
5025018-01 NV 3mm
5025064-01 NV 5mm
T-type Allen key
NV
IT
‘T
5025020-01 (M5)
T
I@
NV
13
2062(372-11 J024332-55
Y
II
.—-
-“a
Stud tightener
5025022-01 NV8mm
5025023-01 NV 10 mm
Nut driver
5025025-01
Holdfast, complete
Ill5025026-01
@
Puller, complete with screw
B5027005-01
6is-
Q
0
\0
\/
5025037-01
Vacuum tester, complete
5025038-01
Pressure tester, complete
5025042-01
Lithium grease, 250 g
5025045-01
Spacer sleeve, 35 mm
5025047-01
Sealing plate, inlet
5025048-01
Sealing plate, exhaust
5025049-01
Pliers, centrifugal
clutch
3:1
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RSpecialtools B
@““ .5025051-01
/
Crimping pliers
o
\,\\\\\\\’ 5025053-01
Sealing ring assembly
socket
5025063-01
Extractor, angle
gear
502
~50250WJl
5025065-01 (M1O)
Puller, gear shaft a
5025070-01 n
5025070-01
Piston assembly kit,
complete
1
I
I
.
(
.
5025078-01
Extractor, sealing ring
5025079-01
Sealing ring assembly
sleeve
5025083-01
Hook for tank weight
5025086-01 NV3mm
5025087-01 NV4mm
5025088-01 NV 5mm
Socket driver with ball
5025090-01
Jet-Pac spray gun, complete
with touch-up paint
5025091-01
Touch-up paint, orange
1/8 Iitre
5025092-01
Propellant gas for Jet-Pac
5025102-01
Assembly jig
5025103-01
Special fixture
3:2
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RSpecialtools B
5025106-01
Glue
5025107-01
Epoxy adhesive
5025108-01
Loctite AA (normal
locking force)
5025109-01
Loctite AAV (high
locking force)
15027004-01 (M12)
Screw for puller
3:3
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165Rc’
A
Fuelsystem,carburetor
Dismantlingthe carburetor
Clamp the clearing saw in fixture No 5025103-01.
Remove the cylinder casing and blow as much dirt as
possible away from the area round the carburetor,
using compressed air.
Remove the sparking plug cover and air cleaner. Do not
yet remove the plastic sleeve over the carburetor adju-
sting screws as this is held in place by anail.
Fig 4:2
Close the choke flap to prevent dirt from entering the
cylinder. Disconnect the fuel line and back off the two
nuts (nut driver No 50250 22-01) holding the carburet-
or in place.
Open the choke flap and pull the carburetor straight
out to the rear.
Fig 4.3
Remove the small nail holding the plastic sleeve in posi-
tion over the adjusting screws and remove the sleeve.
Clean the outside of the carburetor.
Fig 4.4
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.
Fig 4.5
Connect pressure tester No. 5025038-01 to the fuel in-
let on the carburetor and pump it up to apressure of
0.03 MPa (0.3 kgf/cmq).
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.
Fig 4.6
Back off the screw holding the shaft on which the lever
pivots and remove lever, shaft, spring and needle valve.
4:1
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

G
A
Fuelsystem,carburetor
Drill asmall hole (diameter approx. 2mm) in the two
blank plugs and prise the plugs out by means of asharp
object.
Fig 4.7
NOTE:
Exercise care when drilling to avoid damaging the
carburetor housing.
B.Meteringsystem
Check that the adjusting screws are straight and that no
tip is broken.
Inspect the cones for damage.
Fig 4.9
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.
Back off the two adjusting screws and remove the cover
over the pump diaphragm. Remove the diaphragm and
gasket.
Fig 4,10
Fig 4.8
Carefully remove the fuel filter from the carburetor hou-
sing, using asharp object.
Checkingthe carburetor
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).
Inspect the needle valve for wear at the tip and in the
groove for the lever, Fig. 4:1Oshows aworn needle valve
on the left and a new one on the right.
Fig 4:11
4:2
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RG
&l
Fuelsystem,carburetor
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. Mixturearrangements
Blow all fuel passages and jets 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 carburetor housing are not so badly worn that air
might leak past.
Fit replacements if any parts are damaged or worn.
Assemblingthe carburetor
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 carburetor housing
and then the gasket and cover.
Tighten the four cover screws alternately.
B.Meteringsystem
Fit new blank plugs. Press them into place by means of
suitable pin punches or the like:
for the large plug: punch diameter 8mm
for the small plug: punch diameter 4mm
NOTE:
Do not press down on the plugs with such force that they
bend inwards.
In such event they may not seal as intended.
Fig 4:13
Fit the needle valve, lever with shaft, and spring.
Make sure that the spring is mounted in the right posi-
tion.
HELPFULHINT
Thelargesetof sparepartsfor the carburetor carries
order number 5015467-01.
Fig 4:12
Fig 4:14
4:3
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RG
A
Fuelsystem,carburetor
When correctly adjusted, the needle valve lever should
be on a level with the carburetor 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 carburetor as de-
scribed above (see Fig. 4:5).
Then fit the gasket, diaphragm and cover back in place.
NOTE:
The cenfre 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 nssdle H=3/4 turn open
Low speed needle L=1turn open
Fittingthe carburetor to the
cylinder
If the studs holding the carburetor were unscrewed
from the cylinder when backing off the carburetor nuts,
screw the short thread into the cylinder again.
Check that the choke control is in the open position.
Fit the plastic sleeve over the carburetor adjusting
screws and secure it in place with the small nail.
Fig 4:15
Set the choke flap in the open position.
Open the throttle flap fully by pressing on the lever with
your index finger.
Connect the fuel line and check that it has no kinks that
may interrupt the supply of fuel.
Fit the air cleaner in place.
Carburetor tuning
A. Basicsetting
Before tuning the carburetor, proceed as follows:
Clean the air cleaner or fit anew one, if necessary.
Inspect the sparking plug and its electrodes.
Check that the fuel filter is not clogged.
Fig 4:16
After checking the above, turn the carburetor adjusting
screws to the basic setting:
H=3/4 turn, L=1turn
Use screwdriver No. 5016002-01.
Start the clearing saw and warm it up by cutting into a
stump or the like,
Adjust idling speed by turning throttle stop screw Tto a
position where the saw blade tends to rotate, i.e. acom-
paratively high idling speed.
Push the carburetor into position over the studs, mak-
ing sure that the pin of the choke flap shaft correctly
enters the groove in the choke control. Tighten the nuts.
4:4
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

B.Adjustingthelowspeedneedle(L)
Fig 4:18
Carry out fine adjustment as follows:
1.Screw the Lneedle in slowly from the basic setting.
Engine speed will increase and then decrease when
the fuel-air mixture becomes too lean. Note the need-
le setting at which engine speed is highest.
2. Now unscrew the Lneedle and again note the setting
at which engine speed is highest, Note that the engi-
ne will run slower when the fuel-air mixture is too rich.
3. Turn the Lneedle 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 aslightly richer mixture.
4. Set the idling speed by means of throttle stop screw T
to 2200–2300 r/rein.
5. Open the throttle smartly acouple of times to check
that the engine responds.
If it does not, unscrew the Lneedle by an amount cor-
.- .
responding to about three minutes on a clock face.
Try again.
C.Adjustingthe highspeedneedle
(H)
Fig 4:19
G
A
Fuelsystem,carburetor
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 Hneedle
until fourstroking ceases. From this position, back it off
corresponding to ten minutes on a clock face.
If atachometer such as No. 5025036-01 is available, do
not allow the engine to race at more than 11200 r/rein.
Carburetor tuning is now finished and the throttle con-
trol can be released.
NOTE:
Acarburetor that is set to give too weak amixture will
result in aconsiderable power loss. Tune the carburetor
for maximum power and not for maximum speed.
Now adjust the Hneedle to the correct setting as
follows:
4:5
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

G
A
Fuelsystem,carburetor
tracingschedule
m\\\\\\\\\
Uneven idle x x
Stalls when throttle opened
(needs choke) x x xx x
Mixture grows too weak xx x
Receives no fuel xx
—
Hard to adjust xx x
Mixture too rich x
No idle x
Abnormal needle setting x x x
I I IIIIIIII
x
\ \ 1
x x
x
x
4:6
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RElectricalsystem s
A.Faulttracing
Al. 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 aspark occurs between the elec-
trodes when the engine is turned over by means of
the starter, The stop contact should be in position 1.
Fig 5:7
Try with anew sparking plug. If there is still no spark
then check that the connection between plug lead
and sparking plug cap is satisfactory.
Fig 5:2
A2.
A3.
Disconnect the short-circuiting lead from the switch,
Turn the engine over and check whether aspark oc-
curs between the sparking plug electrodes, If it
does, the stop contact is defective and should be re-
placed.
If the ignition system is still ino~erative after carrying
out ch;cks Al and A2, dismantle the starter and a~id;
rail. It is not necessary to remove the tank filler ;ap.
Check that the short-circuiting 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.
Fig 5:3
/45.
Check the secondary winding of the ignition coil by
means of SEM ignition system tester No, 5025124-
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 areading
when set for resistance measurement,
Remove the flvwheel and ianition coil (see B. Dis-
mantling). Tes~the ignition-coil under load.
Note that different makes of ignition 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 astandard 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 G6135E.
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. 50251 24-01.
5:1
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165RElectricalsystem @
Fig 5:5. SEM ignition system tester, type GA2
Connect the module to the instrument as shown in
Fig. 5:5. Vary the position of the module on the
tester until amaximum 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.
Fig 5:6
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. 5025025-01 to the fly-
wheel and back off the nut, using asocket wrench (14
mm).
Fit puller No. 5025026-01 to the holdfast and withdraw
the flywheel.
NOTE:
Rest the flywheel on a clean surface to avoid metal
filings or metal objects being attracted to the magnets.
Fig 5:8
Remove the sparking plug cap. Grasp the connecting
spring inside the cap with apair of flat-nosed pliers (e.g.
50250 06-01) and withdraw spring and lead. Afew
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:
Theprotective sleeve on the short-circuiting /cad contact
need not be removed.
C.Assembly
Fit the armature plate in reverse order to removal. The
short-circuiting lead must be run underthe carburetor
5:2
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

65 RElectricalsystem G
spacer. Exercise care on assembly to avoid damaging
the lead.
Fig 5:1O
After fitting the armature plate in 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. 5:10).
Tighten the screws securing the armature plate. Fit the
flywheel (note the key slot) and other components in re-
verse order to removal.
Fig 5:11
Use special pliers No, 5025006-01 when fitting the
sparking plug cap to the plug lead to ensure satisfactory
connection between contact spring and lead.
We recommend applying grease No. 5025042-01 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
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165Ro
Cylinder,piston 0
Dismantling
Empty the fuel tank.
Clamp the clearing saw in fixture No. 5025103-01.
Remove the cylinder casing and clean the cooling fins of
the cylinder as well as the area round the cylinder base.
Also clean the carburetor and spacer, making sure they
are free from metal filings and dirt.
Dismantle the following:
Starter, sparking plug cap. sparking plug, air cleaner, fuel
line and carburetor.
...
Fig 6:1
Bend the ends of the securing plate aside and back off
the screws retaining the silencer. Note the two screws
securing the bottom of the silencer to the crankcase.
Fig 6:2
Fig 6:3
Place acloth in the crankcase opening to prevent dirf
and foreign objects from dropping into the crankcase.
Remove the gudgeon pin retaining rings, using apair 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.
Remove the four screws securing the cylinder. Use T-
type Allen key No. 5025018-01.
Carefully lift the cylinder straight up.
6:1
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com

165Ro
Cylinder,piston 0
Inspection
FAULT REMEDY
Broken cooling fins
Damaged threads
Binding marks in cylinder wall (particularly
at exhaust port)
Surface coating on cylinder wall worn (chiefly at top
of cylinder)
Binding scratches on piston
In serious cases –change the cylinder.
Repair the threads with HeIi-Coil inserts.
Clean the damaged area with fine emery cloth to remove
adhering aluminium. In the case of deeper binding scrat-
ches the cy/inder and piston should be rep/aced.
Change cylinder and piston.
Clean the damaged area carefully with afine 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 filings.
1Piston ring burnt in its groove Carefu//y remove the piston ring and clean the groove
with extreme thoroughness before reassembly.
Piston ring worn Check the wear by positioning the ring in the lowest part
of the cy/inder. 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.
Assembly
Check that the piston and cylinder are marked with the Use asuitable drift to centre the piston opposite the
same class designation (see Fig. 1:1and the classifica-
tion table). needle bearing in the connecting-rod. Slide the gudgeon
pin into position and fit the circlips in place. Check that
Fig 6:4 Fig 6:5
Check that the gudgeon pin needle bearing is not dama-
ged or worn. Fit it in the connecting rod and lubricate
with afew 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 apair of flat-nosed pliers.
Lubricate the piston with afew drops of two-stroke oil.
Place the cylinder gasket in position on the crankcase.
Position the plastic support in assembly kit No. 50250
70-01 under the piston.
6:2
For Husqvarna Parts Call 606-678-9623 or 606-561-4983
www.mymowerparts.com