101 90 74-26

Workshop Manual

Brush cutters, Trimmers,Pruners, Pruning saws,Hedge trimmers, Ice drills,Blowers

1

© Copyright Husqvarna AB, Sweden

Workshop ManualBrush cutters, Trimmers,

Pruners, Pruning saws, Hedgetrimmers, Ice drills, Blowers

General recommendations ______________________ 2

1. Starter __________________________________ 3

2. Ignition system ___________________________ 25

3. Fuel system _____________________________ 39

4. Centrifugal clutch _________________________ 81

5. Angle gear _____________________________ 107

6. Cylinder and piston ______________________ 119

7. Crankshaft and crankcase _________________ 147

8. Hydraulic unit ___________________________ 181

9. Cutting equipment _______________________ 191

10. Tools __________________________________ 209

The Manual covers the models:265, 250, 252, 240/245

225 / 232 / 235 / 240 RBD322/325

122, 32, Mondo250PS, 235 P

225 H 60 / 225 H 75225AI15, 225AI2518H, 140B, 141B

132HBV, 225BV, 225HBV

Contents

2

502 51 03-01

General recommendations

Bear in mind:● Do not start the engine without the clutch drum and

driveline fitted as the clutch can become detached andcause severe personal injury.

● Do not touch hot components, e.g. the muffler and clutchbefore they have cooled sufficiently to avoid burns.

● Avoid getting fuel or oil on your skin or in your mouth.Use a barrier cream on your hands. This reduces the riskof infection and makes dirt easier to wash away.Long term contact with engine oil can represent a healthhazard.

● Never start the engine indoors. Exhaust fumes are poison-ous!

● Wipe up oil spills from the floor immediately to avoidslipping.

● Do not use tools that are worn or fit badly, for example onnuts and bolts.

● Always work on a clean bench.

● Always work logically to ensure all parts are fitted correctlyand that nuts and bolts are tightened.

● Use the special tools where recommended to be able tocarry out the work correctly and efficiently.

Special toolsSome of the work described in the Workshop Manual requiresspecial tools. In each section where this is necessary there is apicture of the tool and an order number.

We recommend the use of special tools in order to avoidexpensive damage to parts in question and personal injury andto provide an efficient repair procedure.

Contact faces and gasketsEnsure all surfaces are clean and free from gasket residue, etc.When cleaning use a tool that will not damage the contact face.Any scratches or unevenness should be removed using a flatfine cut file.

Sealing ringsAlways replace a sealing ring that has been dismantled. Thesensitive sealing lip can easily be damaged resulting in inferiorsealing capacity. Surfaces which the seal shall seal against mustalso be completely undamaged. Lubricate the sealing lip withgrease before it is fitted and ensure that it is not damaged e.g.by shoulders and splines on a shaft. Use tape or a conical sleeveas protection. It is important that the sealing ring faces in theright direction for it to act as it is intended.

The workshop used to carry out repairs must be equipped withsafety devices in accordance with local directives.

No one may carry out repairs without first having read andunderstood the contents of this Workshop Manual.

The boxes below can be found in appropriate parts of thismanual.

WARNING!

The warning box warns of the risk for per-sonal injury if the instructions are not fol-lowed.

!NOTE!

This box warns of damage to material if the instruc-tions are not followed.

The machine is type approved for safety in accordance withapplicable legislative demands with the equipment specified inthe Operator’s Manual. The assembly of other equipment oraccessories or spare parts not approved by Husqvarna canresult in the failure to meet these safety demands and that theperson carrying out assembly bears responsibility for this.

Poisonous fumesWhen using cleaning agents read the instructions carefully.

Ensure there is good ventilation when handling petrol and othervolatile fluids.

The engine's exhaust fumes are poisonous. Test run the engineoutdoors.

Fire riskHandle fuel with respect as it is extremely inflammable.

Do not smoke and ensure there are no open flames or sparksin the vicinity.

Make sure there is a working fire extinguisher close at hand.

Do not try to extinguish a petrol fire with water.

3

1.Starter

ContentsDismantlingGeneral ______________________________________ 4

Model 265Dismantling, assembly __________________________ 4

Model 250/252Dismantling, assembly __________________________ 7

Model 240/245Dismantling, assembly __________________________ 9

Model 225, 232, 235, 240Dismantling, assembly _________________________ 11

Model 322, 325Dismantling, assembly, replacement of the drive dogs ___ 13

Model 122Dismantling, assembly _________________________ 15

Model 32, Mondo, Mondo MegaDismantling, assembly _________________________ 17

Model 18HDismantling, assembly _________________________ 21

Model 140B, 141BDismantling, assembly _________________________ 22

Assembly, general ____________________________ 24

Replacing the drive dogs _____________________ 24

4

1 Starter

WARNING!Protective glasses must be worn when working on the starter to prevent injuryto the eyes, if for some reason, the return spring should fly out.

!

DismantlingGeneralDismantle the starter from the enginebody.

DismantlingGeneralRemove all bolts and lift off the starter.

On some models the cylinder cover andtank filler cap must be removed.

Model 265DismantlingRelease the spring pressure.

Model 265DismantlingRelease the spring pressure. Pull out thestarter cord approx. 30 cm.Hold the starter pulley with your thumband place the cord in the cut-out on thestarter pulley rim.Let the starter pulley slowly recoil.

NOTE!Stop the spring with your thumb.

! WARNING!Exercise care so that thescrew tip on the cord at-tachment does not injureyour thumb.

Remove the screw and washer in thecentre of the starter pulley and bearingsleeve.

Lift out the starter pulley.

Remove the screw and washer in thecentre of the starter pulley and bearingsleeve.

Lift out the starter pulley carefully so thatthe spring does not follow and fly out.

WARNING!Wear protective glasses.The return spring can flyout and cause personalinjury.

!

5

1

A

B

Starter

Remove the spring from the starter hous-ing.

AssemblyInsert a new spring in the starter housing.

Remove the spring from the starter hous-ing by knocking it against a bench with thespring facing downwards.

WARNING!

Wear protective glasses.!

AssemblyFit a new return spring if necessary.

Let the spring retainer ring remain in place.

1. Place the spring over its seating in thestarter housing

2. Push the spring into its right positionusing your thumb and let the retainerring slide off the spring.

3. Lubricate the spring with a few dropsof oil.

NOTE!

Do not forget the Pertinax disc be-tween the spring and the starterhousing.

! WARNING!Wear protective glasses.

Check the starter pulley's bearing.

If necessary replace the sleeves (A) and(B).

Check the starter pulley's bearing. If it isheavily worn the bearing sleeve (A) canbe replaced.

Cut out the sleeve and press in a newsleeve.

If there is still too much play on the bear-ing a new metal sleeve (B) should also befitted.

If necessary replace the starter cord. If necessary replace the starter cord.

Thread the new cord through the hole inthe starter pulley as shown in the illustra-tion and screw the plastic cube on the endof the cord. Let it protrude approx. 3 mmand melt it using a soldering iron to en-sure a secure fastening is obtained.

6

B

1 Starter

Wind the cord around the starter pulleyabout 3 turns clockwise and position thepulley in the starter housing.

Tip!The knot on the starter cord in the handlecan be difficult to undo. It is easier if youplace the knot on a hard surface and hit itwith a hammer.

Wind the cord around the starter pulleyabout 3 turns clockwise and position thepulley in the starter housing.

Check that the return spring grips thestarter pulley hub correctly.

Fit the washer and screw that hold thestarter pulley.

Lubricate the bearing sleeve (B) with afew drops of oil and insert the starterpulley.

Fit the washer and screw.

Use Loctite on the screw.

Fit the starter handle on the cord. Insert the cord through the cord guide inthe starter housing and anchor it in thestarter handle by tying a knot.

Fold down the free ends and pull the knotfully into the starter handle.

Tension the return spring. To tension the return spring pull out thestarter cord fully and lift it into the cut-outin the starter pulley.

Hold the pulley using your thumb thentension the spring by turning the starterpulley clockwise approx. 2 turns.

7

1

+ 1/2 r

Max

Starter

Check the spring tension. Check the spring tension.

It should be possible to turn the starterpulley at least a further half turn with thestarter cord fully extended.

Model 250DismantlingRelease the spring tension.

Remove the starter pulley.

Model 250DismantlingRelease the spring tension in the sameway as described for model 265.

Remove the screw in the centre of thestarter pulley and lift out the pulley.

Carefully remove the spring cassette sothat the spring does not fly out.

Remove the screws and lift out the springcassette.

Check the starter pulley and starter hous-ing for wear and damage.

Despite the spring sitting in a cassette itcan still fly out when the cassette is priedfrom the guide pin when inserting thecord in the starter housing.

Check the following:

1. Wear on the drive pins on the starterpulley.

If necessary replace the starter cord.

2. Nut in the nut pocket is in position andthe thread is undamaged.

3. Cord entry in the starter housing. Ifworn the housing should be replaced.

! WARNING!Wear protective glasses.

8

1 Starter

AssemblyFit a new spring cassette if necessary.

AssemblyLubricate the return spring with a fewdrops of oil or a cold resistant grease.

Ensure the spring has been pressed downto the bottom of the cassette especially atthe fastening points.

Fit the spring cassette in the starter hous-ing.

Press the spring cassette into the starterhousing and tighten the screws.

Check that the end of the spring is approx.3 mm from the spindle to help assemblyof the starter pulley.

Lubricate the surface of the cassette withoil or cold resistant grease.

Fit a new starter cord. Fit a new starter cord.

Tie a small knot on the cord and melt theends of the cord so that is does not fray.

Wind the cord approx. 3 turns anticlock-wise on the starter pulley.

Tip!First thread the cord straight through thehole in the starter pulley and then backagain and out through the slot.

Fit the starter pulley. Lubricate the spindle in the starter hous-ing with a few drops of oil and position thestarter pulley and tighten the screw.

Fit the starter handle as described formodel 265, but tie a double knot as thecord is lighter.

9

1

Max

+ 1/2 r

Starter

Tension the return spring. To tension the return spring.

Wind the cord 2 turns anticlockwisearound the hub on the starter pulley andpull out the starter handle until the cord isextended.

Repeat the procedure once more.

Check the spring tension. NOTE!With the starter cord fully extended itmust still be possible to turn the starterpulley at least a further half turn.

Models 240/245DismantlingRelease the spring.

Remove the starter pulley.

Models 240/245DismantlingRelease the spring tension as describedfor model 265.

Remove the screw and washer and lift outthe starter pulley.

! WARNING!Wear protective glasses.

Lift out the spring cassette. The spring cassette sits freely in thestarter housing and can easily be liftedout to be replaced.

10

1 Starter

AssemblyCheck the starter housing for wear anddamage.

Fit the spring cassette.

AssemblyCheck the cord guide in the housing. If itis worn the starter housing must be re-placed.

Lubricate the spring with a few drops of oiland position the spring cassette in thestarter housing.

Anchor the starter cord in the starterpulley and wind it approx. 4 turns clock-wise onto the pulley.

Tie a small knot on the cord and seal theends by melting the cord ends, e.g. with asoldering iron.

Anchor the starter cord in the starterpulley and wind it about 4 turns clock-wise around the pulley.

Fit the starter pulley in the starter hous-ing.

Lubricate the bearing spindle with a fewdrops of oil and fit the starter pulley in thestarter housing.

Position the washer and tighten the screw.

Fit the starter handle on the cord. Fit the starter handle as described formodel 265, but tie a double knot as thecord is lighter.

11

1

+ 1/2 r

Max

Starter

Tension the return spring. To tension the return spring

Wind the cord 2 turns clockwise aroundthe hub on the starter pulley and pull outthe starter handle until the cord is fullyextended.

Repeat the procedure once more, butonly wind the cord 1 turn around the hub.

Check the spring tension. Check the spring tension.

Models 225, 232, 235,240DismantlingRelease the spring tension and disman-tle the starter pulley.

Models 225, 232, 235,240DismantlingRelease the spring tension as describedfor model 265.

Remove the screw and washer and lift outthe starter pulley.

Remove the spring cassette. Remove the screw and lift out the springcassette from the starter housing.

! WARNING!Wear protective glasses.

NOTE!With the starter cord fully extended itmust still be possible to turn the starterpulley at least a further half turn.

12

1

Max

+ 1/2 r

Starter

AssemblyCheck the starter housing for wear anddamage.

Fit a new spring cassette if necessary.

AssemblyCheck the cord entry.

If it is worn the starter housing must bereplaced.

Lubricate the return spring with a fewdrops of oil and fit the cassette in thestarter housing.

NOTE!

The end of the spring should be 3–4 mm from the spindle to help as-sembly of the starter pulley.

Fit a new starter cord. Fit a new starter cord. Tie the smallestknot possible on the cord and melt theends to stop it from fraying.

Wind the cord about 3 turns anticlock-wise on the starter pulley.

Position the starter pulley in the starterhousing and fit the washer and screw.

Fit the starter handle. Fit the starter handle as described formodel 265.

Tension the return spring by winding thestarter cord 2 turns anticlockwise aroundthe hub on the starter pulley.

Repeat the procedure once more, butwith the cord only wound once around thehub.

Check the spring tension.NOTE!With the starter cord fully extended itmust still be possible to turn the starterpulley at least a further half turn.

13

1

A

Starter

! WARNING!Wear protective glasses.

The return spring lies tensioned inthe starter and can fly out andcause personal injury with care-less handling.

Models 322, 325DismantlingRemove the 3 bolts and lift off the starter.

NOTE!Ensure the bushings (A) that guide the starter towards the fuel tank are not lost.

Offload the spring tension.

Remove the screw from the centre of thestarter pulley and lift off the starter pulley.

Offload the spring tension in the sameway as described for model 265.

Remove the screw in the centre of thestarter pulley. Carefully lift out the starterpulley from the starter housing.

AssemblyClean the component parts and assem-ble in the reverse order as set out fordismantling.

AssemblyClean component parts before assembly.

Replace the return spring/starter pulleyand starter cord, if necessary.

Assemble the starter pulley.

Assemble a new starter cord.

Lubricate the spindle with a little greaseand fit the starter pulley.

Position the washer and tighten the screw.

Assemble a new starter cord. Slid it intothe starter pulley’s slot as illustrated andthen out through the cord guide in thestarter housing.

Make sure the knot on the end of the cordis as small as possible!

NOTE!

The return spring and starter pulleyare supplied pre-assembled and arefitted in the starter housing as asingle unit.

Exercise care when opening thepackaging so that the spring doesnot fly out.

NOTE!

A new starter cord can be fittedwithout the need of dismantling thestarter!

14

1

504 91 06-05

Starter

Assembling the starter handle. Assemble the starter handle in the sameway as described for model 265, but tie adouble knot as the cord is lighter.

Tension the return spring

Check the spring tension.

Fit the starter on the engine body.

Do not forget the guide sleeves for the fueltank.

Tension the return spring. Pull out thestarter cord fully and lift it out of the cut-out in the starter pulley.

Now turn the starter pulley anticlock-wise, 6 turns.

Check the spring tension. With the startercord fully extended it should still be pos-sible to turn the starter pulley further, atleast a half turn.

Replacing the drive dogsDismantle the drive body.

Replacing the drive dogsFit the piston stop no 504 91 06-05 in thespark plug hole and loosen the nuts hold-ing the drive body.

Remove the circlip and replace any dam-aged drive dogs or springs, if necessary.

Remove the circlip holding the drive dog.

Lift out the drive dog and spring for re-placement.

Assemble in the reverse order as set outfor dismantling.

15

1

2

1

Starter

Replace the drive dog if it is damaged orworn.

The drive dog and its spring can easily bereplaced if damaged or worn.

Squeeze together the drive dog's axlestud with pliers when dismantling.

Unscrew the hub from the crankshaft.

Use a hammer and punch to loosen thehub if necessary.

Remove the starter hub from the crank-shaft.

Dismantle the starter from the enginebody.

Remove the screws and lift off the starterfrom the engine body.

Model 122DismantlingRemove the covers from the muffler andcylinder.

Model 122DismantlingYou must first remove the covers over themuffler and cylinder to be able to disman-tle the starter.

Remove the screw (1), pull out the loweredge of the cover and lift it off.

Remove the screw (2) and lift off thecylinder cover.

NOTE!

The nut is brazed on the drive.

16

1 Starter

! WARNING!Wear protective glasses.

! WARNING!Wear protective glasses.

Release the spring tension and disman-tle starter pulley.

Release the spring tension as describedfor model 265.

Remove the screw and washer and care-fully lift out the starter pulley so that thereturn spring does not fly out.

AssemblyFit a new return spring in the starter unit.

AssemblyFit a new return spring in the starter unit.

Press the spring down correctly on thefastener and lubricate with a few drops ofoil or cold resistant grease.

Ensure the ends of the spring are 2-3 mmfrom the spindle.

Fit a new starter cord and position thestarter pulley in the starter housing.

Fit the starter handle.

Tension the return spring.

Fit a new starter cord. Tie the smallestknot possible on the cord but leave freean end of approx. 10 mm.

Press the free end into the cut-out in thepulley hub reinforcement.

Wind the cord about 4 turns clockwise(seen from the rear) on to starter pulley.

Position the starter pulley in the starterhousing and fit the washer and screw.

Fit the starter handle as described formodel 265, but tie a double knot on thecord.

Lift up the starter cord from the cut-outand wind it 2 turns anticlockwise aroundthe hub on the starter pulley. Pull out thestarter handle until the cord is fully ex-tended.

Repeat the procedure once again.

17

1

Max

+ 1/2 r

Starter

Disconnect the electrical cables.

Remove the shaft complete with handles.

Disconnect the electrical cables by theengine body and remove the 4 screws(models Mondo and Mondo Mega have 3screws) that hold the shaft and handle onthe starter housing.

Lift off the shaft.

Lift out the throttle cable. Move the throttle trigger forward and liftthe throttle cable out of the trigger.

Models 32, Mondo,Mondo MegaDismantlingRemove the screws that hold the throttletrigger.

Models 32, Mondo,Mondo MegaDismantlingRemove the screws that hold the throttletrigger and slide it along the shaft as far asthe throttle cable and electrical cables willallow.

Check the spring tension.NOTE!With the starter cord fully extended itmust still be possible to turn the starterpulley at least a further half turn.

Fit the hub, starter and covers in thereverse order set out for dismantling.

18

1 Starter

Dismantle the centrifugal clutch. Undo the nuts holding the centrifugalclutch and lift off the clutch and the largewasher.

Dismantle the starter. Remove the 4 screws and lift off thestarter.

Model 32Pull out the electrical cables from thestarter housing using flat nose pliers.

Model MondoAlso dismantle the screw by the sparkplug.

Remove the two locking plates that holdthe starter pulley axially.

Remove the two locking plates that holdthe starter pulley axially.

Release the spring tension. Release the spring tension.

Pull out the starter cord about 30 cm andplace the cord in the cut-out on the edgeof the starter pulley.

19

1Starter

! WARNING!Wear protective glasses.

! WARNING!Wear protective glasses.

! WARNING!

Take care so that yourthumb is not injured bythe cord's fasteningscrew.

Replace the starter cord and attach it asshown in the diagram.

Attach the new starter cord to the starterpulley and wind it about 3 turns clock-wise around the pulley.

AssemblyInsert a new spring cassette in position inthe starter housing.

AssemblyLubricate the return spring with a fewdrops of oil and position the new springcassette in the starter housing.

If the spring, despite your being careful, hasflown out reposition it again in the cassettewith the end turned as shown in the picture.

Remove the return spring from the starterhousing.

Exercise great care when removing thestarter spring.

The spring is tensioned inside a sheetcassette, nevertheless it can still easilyfly out when dismantled.

Let the starter pulley slowly rotate back-wards.

Lift off the starter pulley.

Let the starter pulley slowly rotate back-wards (anticlockwise) and then lift off thepulley.

NOTE!

Stop the rotation using your thumb.

20

1

Max

+1/2 r

Starter

Fit the starter pulley. Lubricate the pulley spindle with a fewdrops of oil.

Ensure the end of the spring is about 2–3 mm from the spindle and position thestarter pulley.

NOTE!

Do not tighten the locking platesthat hold the starter pulley axially.

Fit the starter handle. Fit the starter handle as described formodel 265.

Tie a double knot as the cord is lighterthan on model 265.

Tension the return spring. Tension the return spring.

● Pull out the cord approx. 30 cm andstop the starter pulley with your thumb.

● Lift the cord up from one of the cut-outs on the starter pulley.

● Wind the cord 2 turns clockwisearound the hub on the starter pulley.

● Pull out the starter cord fully.

Repeat the spring tensioning and fit thelocking plates.

Repeat the spring tensioning once more.

Ensure the starter pulley can still be turnedat least a further half turn with the cordfully extended.

Tighten the locking plates that hold thestarter pulley axially.

NOTE!

Model 32 has a thin spacer underthe plates.

21

1

504 91 06-06

Starter

The following procedures are the same as for models 32, Mondo:

Remove the locking plates holding the starter pulley axially.

Offload the spring tension.

Dismantle the starter pulley and spring cassette from the starter housing.

Dismantle the starter from the engine. Dismantle the starter.

Remove the 5 screws holding the starterhousing

Lubricate the ignition cable with a fewdrops of oil and remove the rubber grom-met in the cover.

Lift off the starter housing.

Dismantle the centrifugal clutch. Assemble the piston stop no. 504 91 06-05 in the cylinder.

Unscrew the centrifugal clutch. Firstloosen it using a hammer and punch,anticlockwise.

Model 18HDismantlingDismantle the air filter, throttle cable andcarburettor.

Remove the 4 screws holding the enginebody and gear housing.

Model 18HDismantlingThe starter is positioned between thecrankcase and the cutting equipmentdrive.

First dismantle the spark plug, air filter,throttle cable and carburettor.

Turn the mower upside down so that thescrews holding the engine body are ac-cessible. Remove the 4 screws.

22

1 Starter

Assembly (also see model Mondo)

Place a new spring cassette in position in the starter housing.

Replace the cord and attach as illustrated.

Assemble the starter pulley.

Assemble the starter handle (see model 265).

Tension the return spring.

Repeat tensioning the spring and fit the locking plates.

Models 140B, 141BDismantlingRemove the screws and lift off the starter.

Models 140B, 141BDismantlingRemove the 4 screws holding the starteragainst the engine body.

Offload the spring tension and removethe starter pulley from the starter hous-ing.

Lift the starter cord out of the cut-out inthe starter pulley.

Offload the spring tension by allowing thestarter pulley to rotate backwards. Stopthe pulley using your thumb.

Remove the screw and washer from thecentre of the starter pulley.

Lift off the starter pulley.

Dismantle the return spring.

Clean and replace any damaged parts.

Carefully lift off the starter pulley andreturn spring.

The return spring lies tensioned in thestarter housing and can fly out and causepersonal injury with careless handling.

Clean and replace any damaged parts.

! WARNING!Wear protective glasses.

23

1Starter

Tension the return spring.

Check that the pulley can be turned afurther half turn with the starter cord fullyextended!

Tension the return spring.

● Pull out the cord approx. 30 cm andstop the starter pulley using yourthumb.

● Lift the starter cord up in the cut-out inthe starter pulley.

● Wind the cord 2 turns anticlockwisearound the hub on the starter pulley.

● Pull out the starter cord fully.

Assemble the starter handle. Assemble the starter handle.

The collar on the washer should facetowards the starter handle.

Replace the starter cord and attach asillustrated.

Wind the cord 4 turns clockwise aroundthe starter pulley.

Lubricate the spindle and return springand assemble the starter pulley.

Attach a new starter cord in the starterpulley as illustrated.

Wind the cord 4 turns clockwise aroundthe starter pulley.

Lubricate the spindle and return springwith a few drops of oil.

Place the starter pulley in position andtighten the screw in the centre. Do notforget the washer.

AssemblyFit a new return spring in the starterhousing. Exercise great care so that itdoes not fly out.

AssemblyFit a new return spring in the starterhousing.

Check that the spring’s mounting is fac-ing the right way!

! WARNING!Wear protective glasses.

24

503 21 22-01

1 Starter

Models 140B, 141BDrive dogsDismantle the drive from the crankshaft.

Replace the drive dogs if they are dam-aged or worn.

Models 140B, 141BDrive dogsDismantle the drive dog from the crank-shaft.

Unscrew the nut (anticlockwise) and thenunscrew the drive in the same direction.

Replace the drive dogs if they are dam-aged or worn.

Fit the new dog in the hole marked “R”.

Assembly, generalAssemble the starter following the re-verse order set out for dismantling.

Replacing the drivedogsSee chapter 2. “Ignition system, flywheel”with regard to engines that have the drivedogs fitted on the flywheel.

Replacing the drivedogsSee chapter 2. “Ignition system, flywheel”with regard to engines that have the drivedogs fitted on the flywheel.

Assembly, generalAssemble the starter.

Pull out the starter cord a little. Positionthe starter. Release the starter cord andensure that the drive dogs grip in thestarter pulley.

Tighten the screws.

NOTE!If the plastic threads in the crank-case have, for some reason,been damaged it is recom-mended to use an over dimen-sioned screw (no 503 21 22-01).

25

2.Ignition system

ContentsChecking the spark ________________________ 26

Replacing the spark plug cap ________________ 28

Dismantling ______________________________ 29

Dismantling the flywheel ____________________ 33

Drive dogs _______________________________ 34

Assembly _______________________________ 36

Technical data ____________________________ 38

26

2

502 71 13-01

Ignition system

The ignition spark in an electronic ignition sys-tem has a very short burn time and can bejudged to be weak and is at times difficult to seewhen trouble shooting.

The engine is equipped with an electronic ignitionsystem with no moving parts. Consequently, a faultycomponent cannot be repaired, but must be replacedwith a new one.

Checking the sparkAll modelsClean the electrodes and check the elec-trode gap.

Checking the sparkAll modelsRemove the spark plug and clean off anycarbon deposits using a wire brush.

Check the electrode gap, it should be 0.5mm.

Adjust the gap to the correct size usingthe side electrode.

If the electrodes are worn by more than50% the spark plug should be replaced.

If the electrodes are worn by more than50% the spark plug should be replaced.

An excessive spark gap can overload theignition module and risk short circuiting.

Ensure the stop switch is in the 'start'position.

Check whether there is a spark whenattempting to start, if not test using sparkplug no. 502 71 13-01.

Earth the spark plug against the cylinderand pull the starter handle sharply.

There should now be a spark between theelectrodes.

If there is no spark try using the test sparkplug no. 502 71 13-01.

If there is spark now the spark plug isfaulty.

Fit a new spark plug.

27

2

A

B

Ignition system

Check other cables and connections. Still no spark?

Check other cables and connections forbad contact (dirt corrosion, cable breaksand damaged insulation).

Tip!Use an ohmmeter to check whether thereis a broken cable caused by crushing, forexample.

Lubricate the cable ends with grease. Lubricate the cable ends with a littlegrease to facilitate assembly and to pre-vent dampness from entering the con-nections.

Check the ignition lead's connections. Still no spark?

Check the spark plug connections.

Pull back the rubber covers by the sparkplug (A) and the ignition module (B) andcheck that the ignition cable is not dam-aged. Cut off a piece of the cable to givea good connection if required.

Fit a new spark plug.

If there is no spark disconnect the stopswitch.

Replace the switch if necessary.

Fit a new spark plug.

If the procedure does not produce a sparkremove the short circuit cable from eitherthe ignition module or the stop switch.

If there is now a spark the stop switch isfaulty.

Replace the switch.

28

2

502 51 34-02

502 50 06-01

531 00 48-61 Model 122

Ignition system

Check the air gap. Still no spark?

Check the air gap between the flywheel'smagnet and the ignition module. The gapshould be 0.3 mm.

Use air gap gauge 502 51 34-02.

Model 122 should have a 0.38 mm gap.Use air gap gauge 531 00 48-61

Adjust the air gap. Adjust the air gap to the right measure-ment.

● Loosen the screws.

● Insert the gauge and press the igni-tion module against the flywheel.

● Tighten the screws and check the airgap once again.

If there is still no spark the ignition systemshould be replaced.

Changing the spark plugcover1. Push the ignition cable through the

spark plug cover.

2. Make a hole in the ignition cable forthe contact spiral.

Changing the spark plugcover1. Lubricate the ignition cable using a

little grease and push it through thespark plug cover.

2. Cut off a piece of the ignition cable(about 5 mm) and make a hole in thecable for the contact spiral using thepliers no. 502 50 06-01.

3. Fit the contact spiral on the ignitioncable.

3. Fit the contact spiral on the ignitioncable, taking care to form the wirealong the cable.

4. Pull the contact spiral into the sparkplug cover.

NOTE!

It is important that the point of thecontact spiral is positioned so thatit's unable to pierce the spark plugcover.

29

2

504 90 00-03

504 90 00-02

A

B B

B

A

C

Ignition system

Model 122Pull apart the connectors (A).

Remove the throttle cable at (B).

Remove the screws (C) and lift off theshaft.

Model 122Pull apart the connector on the electricalcables (A) and remove the throttle cablefrom the carburettor lever (B).

Remove the screws (C) and lift off theshaft.

Dismantle the ignition module and thecentrifugal clutch.

Remove the remaining screws (A) hold-ing the ignition module and both screws(B) that hold the centrifugal clutch.

Lift off the clutch and ignition module.

Remove the clutch cover and loosen theshort-circuit cable from the ignition mod-ule.

Remove the three screws holding theclutch cover.

Remove the clutch cover complete withthe shaft from the engine.

Loosen both ends of the short-circuit ca-ble from the ignition module.

DismantlingGeneralRemove all components necessary togain access to the flywheel and ignitionmodule.

Models 322, 325Dismantle the guard over the muffler.

Disconnect the throttle cable and removethe screws holding the clutch cover.

DismantlingGeneralDismantle the cylinder cover, spark plug,starter and air guide rail.

Models 322, 325In addition to the components mentionedabove, you also need to dismantle theguard over the muffler.

Disconnect the throttle cable from thecarburettor.

30

2

531 00 48-62

A

B

B

Ignition system

Models 32, MondoRemove the starter.

Dismantle the fan cover and the centrifu-gal clutch.

Models 32, MondoRemove the starter. See chap. 1 “Starter.”

Remove the screws and lift off the fancover.

Dismantle the centrifugal clutch by loos-ening the two bolts.

Dismantle the ignition module and loosenother cable connections.

Dismantle the ignition module by unscrew-ing the two bolts.

Loosen the other cable connections andlift out the ignition module.

Model 18HRemove the spacer and washer and screwthe clutch down on the crankshaft.

Hold the flywheel and sharply tap theclutch a few times until the flywheel re-leases.

Model 18HRemove the long spacer and washer fromthe crankshaft.

Screw down the clutch a few turns on theshaft.

Hold the flywheel and sharply tap theclutch a few times until the flywheel re-leases.

Dismantle the ignition module. Dismantle the ignition module.

Remove the short-circuit cable (A) andboth screws (B).

NOTE!

Hold the clutch carefully using apipe grip so that the soft clutchlinings are not damaged.

We recommend the use of tool no.531 00 48-62.

Notice which way the clutch faces.The “L”-markings on the clutchshoes face outwards.

31

2

A

B

Ignition system

Remove the blower pipe. Loosen the hose clip and remove theblower pipe.

Fold open the protective sleeve and sepa-rate the throttle cable.

Open the protective sleeve over the cablejoint and lift out the throttle cable runningto the throttle.

Pull apart the short-circuit cable connec-tor and remove the earth cable.

Separate the connectors for the short-circuit cable (A) and remove the earthcable (B) by removing the crankcasescrew.

Models 140B, 141BDismantle the fuel tank.

Models 140B, 141BEmpty the fuel tank and pull off the fuelhoses from the carburettor.

Note how the hoses are connected.

Remove the screws and lift off the fueltank.

32

2

A

A

A

B

AA

502 50 22-01

504 91 06-05

Ignition system

Dismantle the impeller. Screw in the piston stop no. 504 91 06-5in the spark plug hole and remove the 3screws holding the impeller using tool no.502 50 23-01.

Remove the pipe bend.

Remove all screws and separate bothhalves of the fan housing.

Remove the pipe bend.

Remove the cleaning cover and all thescrews (12) holding both halves of the fanhousing.

Separate the halves.

Dismantle the harness. Remove the harness from the tubularframe by removing both screws (A).

Dismantle the cylinder cover, heat guardaround the cylinder and the rotary valvefrom the carburettor.

Lift off the spark plug cap and unscrewthe spark plug.

Remove the 3 screws (A) holding thecylinder cover and remove this and theheat guard from around the cylinder.

Dismantle the rotary valve (B) from thecarburettor by removing the 2 screwsholding the cover. Let the throttle hangfrom the throttle cable.

33

2

502 50 22-01

502 50 23-01

504 91 06-05

502 51 49-01

Ignition system

Dismantle the engine from the fan hous-ing.

Remove the 4 screws holding the engineagainst the fan housing.

Lift off the engine.

Remove the screws and lift off the ignitionmodule.

Remove the screws and lift off the ignitionmodule with the ignition lead, short-cir-cuit cable and grommet.

Dismantling theflywheelFit the piston stop no. 504 91 06-05 andremove the nut holding the flywheel andwhere appropriate the plate with drivedogs.

Dismantling theflywheelAssemble the piston stop no. 504 91 06-05 in the spark plug hole.

Ensure the piston stop is screwed downto the bottom.

Remove the nut holding the flywheel andwhere appropriate the plate with drivedogs.

NOTE!The piston stop cannot be used on model122.

Dismantle the flywheel by using the fly-wheel puller.

Dismantle the flywheel from the crank-case using the puller no. 502 51 49-01.

Gently knock the puller screw with a ham-mer, if the flywheel sits tightly on thecrankshaft.

Select suitable screws and align the pullerso that it does not pull at an angle.

34

2

505 38 17-05

504 90 90-01

502 51 94-01

Ignition system

Dismantle the flywheel by using the bear-ing puller.

Pull off the flywheel using the bearingpuller no. 504 90 90-01.

Dismantle the flywheel by using a ham-mer and push bar.

Screw the nut on the axle to protect thethread.

Unhook the springs and fold back thedrive dogs to give a little room for thehammer.

Grip the flywheel and lift up the enginebody.

Apply a few sharp blows with a hammeron the flywheel nut until the flywheel freesitself from the axel.

Tip!Use the push bar to protect the tread atthe same time as it is easier to use thehammer.

Do not screw the push bar completely upto the flywheel – leave about 2 mm.

Drive dogsGeneralCheck the drive dogs with regard to wearand cracking.

Replace damaged components.

Drive dogsGeneralCheck the drive dogs with regard to wearand cracking.

Replace damaged components.

The entire unit must replaced if the drivedogs are fitted on a separate bridge.

Dismantle the locking clip. Turn the locking clip so that the openingaligns with the centre of the flywheel.

Use, e.g. punch no. 505 38 17-05 andpress off the clip.

Is the flywheel really tight?

Lift up the engine body by holding thepuller and knock the puller screw a fewtimes with a hammer.

NOTE!The arms on the puller should beplaced by and opposite the magnet onthe flywheel to avoid damaging it.

35

2Ignition system

Models Mondo, 18HThe drive dogs can be dismantled oncethe screws on the opposite side of theflywheel have been removed.

Models Mondo, 18HOn these models the drive dogs are heldin place by screws, tightened from theopposite side of the flywheel.

Dismantle the bolts and lift off the drivedogs.

Replace damaged parts. Replace damaged parts.

Ensure the springs are not crushed whenthe stud is pressed into the flywheel.

Check that the drive dogs move easily.

Press out the bearing studs using a suit-able punch.

Replace the drive dogs and springs asfollows if they are journalled on a studpressed into the flywheel:

Place the flywheel on support blocks andpress out the studs using a suitable punch.

Dismantle the drive dogs and the returnspring.

Unscrew the bearing pin.

Replace any damaged parts.

Check that the drive dogs move easily.

Dismantle the drive dogs and the returnspring.

Unscrew the bearing pin.

Replace any damaged parts.

NOTE!

The spring clip's opening shouldbe turned outwards between thefan fins.

36

2

502 51 34-02

Ignition system

AssemblyCheck that the keyway and key on thecrankshaft are not damaged.

AssemblyCheck that the keyway and key on thecrankshaft are not damaged.

Fit a new key if necessary and ensure itsits correctly in the keyway.

Check that the keyway and cast key onthe flywheel are not damaged.

Fit the flywheel.

Check that the keyway and cast key onthe flywheel are not damaged.

Fit the flywheel on the crankshaft andcheck that key and keyway are correctlyaligned before the flywheel nut is tight-ened.

Tighten the nut to a torque of 25–35 Nm.

Models 322, 325Assemble the centrifugal clutch.

Models 322, 325If the crankshaft has two keyways, theflywheel should be fitted in the right-handkeyway seen from the axle end.

Assemble the centrifugal clutch.

Assemble the ignition module and adjustthe air gap to 0.3 mm.

Assemble the ignition module.

Wait to connect the short-circuit cable tofacilitate the adjustment of the air gap. Itshould be 0.3 mm between the perma-nent magnets in the flywheel and theignition module.

Now fit the short-circuit cable and theremaining parts in the reverse order asset out for dismantling.

NOTE!

Do not forget the rubber bush-ings between the clutch cover andthe fuel tank.

NOTE!

Do not forget the washers betweenthe flywheel and centrifugal clutch.

NOTE!

Do not forget the washers betweenthe flywheel and centrifugal clutch.

NOTE!

If the crankshaft has two keywaysit is the keyway that is open all theway out to the thread which isused if the flywheel has a cast key.

37

2Ignition system

Model 122Turn the centrifugal clutch so that the “L”-marking on the clutch shoes is facingoutwards.

Model 122As the centrifugal clutch is fitted on theflywheel it is important that it is positionedso that the “L-marking” on the shoes facesoutwards.

“L” means left rotation.

All modelsFit the ignition module.

Adjust the air gap (0.3 mm).

Fit the other cables.

Fit the remaining components in the re-verse order set out for dismantling.

All modelsFit the ignition module.

Adjust the air gap (0.3 mm).

Also see page 26.

Fit the other cables and ensure they sitcorrectly in the cable channels, etc. sothat they cannot be damaged.

Fit the remaining components in the re-verse order set out for dismantling.

Model 250Do not forget to fit the heat guard for theignition cable.

Model 250Fit the earth cable using the AMP connec-tor on the ignition module before it isscrewed onto the crankcase.

NOTE!

Do not forget the plastic compo-nents that protect the ignition ca-ble from the radiant heat from themuffler.

38

2

Mondo Champion RCJ8Y 0.5/0.02 Phelon 0.3/0.012NGK BPM 6A CD

122L NGK BPM 6Y 0.6/0.024 Ikeda Denso 0.3/0.012Solid State

Mondo Max Champion 0.5/0.02 Phelon 0.3/0.012RCJ 8Y CD

225L/LD Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

232L Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

Mondo Mega Champion 0.5/0.02 Phelon 0.3/0.012RCJ 8Y CD

225R/RD Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

232R Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

322 Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

325 Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

235R Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

240R Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

245R Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

250R Champion 0,5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

245RX Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

250RX Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

252RX Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

265RX Champion 0.5/0.02 SEM 0.3/0.012RCJ 7Y GA6 CD

240RBD Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

235P Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

250PS Champion 0.5/0.02 Electrolux 0.3/0.012RCJ 7Y ET

225E Champion 0.5/0.02 Walbro 0.3/0.12RCJ 7Y CD

18H Champion 0.5/0.02 Phelon 0.3/0.012RCJ 8Y Solid State

225H60/75 Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

140B/141B NGK 0.6–0.7/ Kawasaki 0.4/0.016BPM 7A 0.024–0.028 Transistor

132HBV Champion 0.6/0.024 Phelon 0.25–0.35/CJ 8Y CD 0.010–0.014

225BV/225HBV Champion 0.5/0.02 Walbro 0.3/0.012RCJ 7Y CD

Ignition system

Technical data

Model Spark plug Electrode gap Ignition Air gapmm/inch system mm/inch

39

3.Fuel system

ContentsAir filter __________________________________ 40Tank venting ______________________________ 41Fuel filter _________________________________ 43Primer pump ______________________________ 44Carburettor design _________________________ 48Carburettor settings ________________________ 63CARB-designed carburettor __________________ 65Throttle __________________________________ 68Throttle cable _____________________________ 71Technical data _____________________________ 79

40

3

A

505 69 85-70

Fuel system

ments to the carburettor setting or air filter block-age have a great effect on how the engine runsand its efficiency.The carburettor on our models can come fromseveral manufacturers, but the operation andrepair techniques are essentially the same.

The fuel system comprises, in addition to the fueltank and the carburettor, the air filter, fuel filter andtank venting.All these components interact so that the enginereceives the optimum mixture of fuel and to make itas efficient as possible. Extremely small adjust-

Air filterDismantle the cylinder cover and air filtercover so that the filter is accessible.

Air filterDismantle the cylinder cover and air filtercover so that the filter is accessible.

The air filter material can either be offoam or of fine mesh nylon weave.

Both types are cleaned in tepid, soapywater.

Damaged filters shall be replaced with anew filter.

The air filter material can either be offoam or of fine mesh nylon weave.

Both types are cleaned in tepid, soapywater.

Damaged filters shall be replaced with anew filter.

Model MondoDismantle the air filter cover and lift outthe air filter for cleaning.

Model MondoDismantle the air filter cover and lift outthe air filter for cleaning.

! WARNING!Do not clean the filter inpetrol. Hazardous!

Tip!Use Husqvarna's cleaning agent ActiveCleaning no. 505 69 85-70.

NOTE!

The filter must be dry when its refit-ted.

NOTE!

It is important when refitting thatthe filter support (A) is notforgotten. Otherwise particlesfrom the air filter can be drawninto the carburettor.

41

3

502 50 37-01502 50 38-01

502 50 37-01502 50 38-01

A

Fuel system

Pressure test the valve using pressureand vacuum.

Pressure test the valve using pressureand vacuum.The valve should open at:

Pressure: 25–30 kPa (0.25–0.30 bar)Vacuum: 25–30 kPa (0.25–0.30 bar)

Replace the complete valve and hose if itis faulty.

Apply a small amount of grease on thehose connection to facilitate fitting thevalve in the tank.

Model 122Dismantle the valve complete with hoseby pulling it upwards.

Model 122The valve is located on this model by thecarburettor and can easily be dismantledfrom the tank for inspection. If necessarypull it up with the help of a screwdriver.

Tank ventingCheck that the tank venting valve func-tions.

Change the tank cap on most models ifthe valve is faulty.

Tank ventingOn most models the tank venting is lo-cated in the fuel cap. It is important for theoperation of the engine that it works.

● Remove the fuel pipe from the carbu-rettor and empty the fuel from the tank.

● Connect the fuel pipe to the pressuretester no. 502 50 38-01 resp. vacuumtester no. 502 50 37-01.

● Pump a pressure resp. underpressureof 50 kPa (0.5 bar) in the tank.

● The pressure should drop to 20 kPa(0.2 bar) resp. return to normal pres-sure within 45 seconds.

Model 141BRemove the air filter cover and lift out theair filter for cleaning.

Model 141BPress down the catch on the cover overthe air filter housing and remove the coverand the air filter for cleaning.

Clean the filter in the same way as de-scribed above.

Fit the filter with the smooth side facing intowards the carburettor.

Ensure the support grille (A) is in position.

42

3

A

502 50 37-01

502 50 37-01

Fuel system

Model 32The venting valve is located in the tank.Check that it functions using the vacuumtester 502 50 37-01.

Model 32The venting valve is inserted in the tank.To gain access for inspection or replace-ment it is necessary to dismantle thecylinder cover and the starter.

Remove the fuel pipe from the carburettorusing a pair of flat pliers and connect thepipe to the vacuum tester 502 50 37-01.

Lower the pressure to –50 kPa (0.5 bar).

Replace the valve if it does not open forvacuum in the tank.

The pressure should normally drop after20 seconds.

If this is not the case the valve should bereplaced.

Press the down valve in the tank using asuitable punch and press in a new valve.

Models Mondo, 18HThe venting valve sits in the tank cap.

Models Mondo, 18HThe venting valve sits in the tank cap.

To pressure test it and gain access to thefuel pipe the carburettor cover must beloosened and swung to the side (Mondo).

Remove the air filter support (A) and bothbolts that hold the carburettor cover andthe carburettor(Mondo).

Empty the fuel from the tank.

Check the valve using the vacuum tester502 50 37-01.

Note where the bolts are positioned sothat they can be repositioned correctlywhen assembling (Mondo).

Empty the fuel from the tank.

Dismantle the pipe, which runs from thefuel tank to the primer pump, from thepipe connection.

Connect the vacuum tester 502 50 37-01.Reduce the pressure to –50 kPa (0.5bar). The pressure should return to thenormal pressure within 20 seconds.

Clean or replace the fuel cap if neces-sary.

NOTE!

The valve only opens for vacuumin the tank.

43

3

502 50 83-01

B

A

A

Fuel system

Fuel filterAll modelsThe fuel filter can be removed through thetank's filler hole.

Fuel filterAll modelsA fuel filter is located on the fuel pipe. It isaccessible through the filler hole. Pull outthe filter using your fingers or using tool502 50 83-01.

If the valve does not work as intended itshould be replaced.

Dismantle the air filter holder and swingout the carburettor.

Pry up the non-return valve from the fueltank using a screwdriver.

Replace the valve if its performance is notsatisfactory.

Models 225 H60, 225 H75Tank ventilation consists of a non-return valve (A) that opens for vacuum and pressure.It is located in the carburettor housing.

● Empty the fuel tank and tighten the fuel cap.

● Clean the filter (B).

● Remove the fuel pipe from the carburettor and connect the pressure tester 502 50 38-01 resp. vacuum tester 502 50 37-01 to the pipe.

Pressure: Pump a pressure of 50 kPa (0.5 bar), the pressure should drop to20 kPa (0.2 bar) within 60 seconds.

Vacuum: Reduce the pressure to –50 kPa (0.5 bar).The pressure should rise again to –20 kPa (0.2 bar) within 30 seconds.

Model 141BThe tank ventilation is integrated in thefuel cap’s gasket

Blow through the flat hose to check that itis open.

Model 141BThe tank ventilation is integrated in thefuel cap’s gasket and can easily be dis-mantled for replacement.

Pull off the flat hose from the pin on therubber washer and blow through the hoseto check that it is not blocked.

Check that the hole (A) is open.

NOTE!

Fit the new valve with the shortshoulder towards the fuel tank.

44

3

A

Fuel system

Clean the outside of the filter if it is tooheavily contaminated.

Replace the filter if necessary.

If it is too heavily contaminated it can becleaned on the outside using a brush.

In all other cases it should be replaced.

Check the fuel pipe with regard to crack-ing and leakage.

Primer pumpModels 322, 325, Mondo, 18HThe primer pump facilitates cold starts.

The pump cannot be repaired and mustbe replaced if it stops working.

Note how the fuel hoses are connected tosimplify assembly.

Primer pumpModels 322, 325, Mondo, 18HThe primer pump has the task of facilitat-ing the start of the engine when cold. Thepump fills the carburettor with fuel beforeattempting to start the engine. This alsoprevents vapour bubbles from blockingthe narrow fuel channels.

If the pump does not work it must bereplaced.

Note how the fuel hoses are connected tosimplify assembly.

CarburettorDismantling all modelsDismantle the cylinder cover and blow outthe carburettor compartment with com-pressed air.

CarburettorDismantling all models● Dismantle the cylinder cover.

● Close the choke damper to prevent dirt from entering the engine.

● Blow out the carburettor compartment with compressed air.

Dismantle the carburettor. Dismantle the air filter and air filter holder,fuel pipe, throttle cable and choke lever.

Lift out the carburettor.

Tip!Let the lower screw (A model 245) remainin the crankcase. This simplifies subse-quent assembly.

NOTE!

Ensure that the filter's connectionshoulder is press into the fuel pipeas far as possible.

45

3

A

1

22

3

Fuel system

Model MondoLoosen and turn the carburettor to theside.

Model MondoRemove the filter support (A) and bothscrews that hold the carburettor coverand the carburettor.

Note where the screws are placed so thatthey can be positioned correctly whenassembling.

Model 122Disconnect the throttle cable from thecarburettor. Fold down the air filter coverand dismantle the carburettor.

Model 122Disconnect the throttle cable from thelever arm on the carburettor.

Press down the snap-lock and swing downthe air filter so that the screws holding thecarburettor are accessible.

Lift off the carburettor and note how thefuel hoses are connected.

Lift off the carburettor and note how thefuel hoses are connected.

Models 322, 325Disconnect the throttle cable from thecarburettor.

Dismantle the carburettor.

Models 322, 3251. Disconnect the throttle cable from the

lever arm on the carburettor.

2. Loosen the carburettor screws.

3. Remove the screws holding the airfilter holder.

46

3

A

B

Fuel system

Bend out the throttle cable.

Remove the fuel pipes.

Bend out the throttle cable.

Remove the fuel pipes. If they are hard toremove, use a screwdriver to press themoff.

Note how the hoses are fitted so they canbe correctly reassembled.

Model 32Dismantle the air filter cover with filter.

Model 32The carburettor is located on the crank-case and becomes accessible when the 3screws and the air filter cover and air filterare removed.

Dismantle the carburettor screws and liftout the carburettor.

Remove the carburettor screws, chokelever and cover plate.

Note how the washers on the choke leverscrews sit.

Now lift out the carburettor.

Model 18HDisconnect the throttle cable from thecarburettor.

Model 18HDisconnect the throttle cable from thecarburettor.

Remove the screw (B) and unhook thethrottle cable from the lever arm on thecarburettor (A).

47

3

A

BB

A

C

A

A

AB

Fuel system

Remove the screws and lift out both dis-tance pieces.

Inspect the fibre distance piece with re-gard to crack formation.

Replace the distance piece if necessary.

Remove the screws (A), the fibre distancepiece (B) and the aluminium distancepiece (C).

Inspect the fibre distance piece with re-gard to crack formation. Replace the dis-tance piece if necessary.

Dismantle the carburettor from the cylin-der.

Remove the air filter support (A) and bothscrews (B) that hold the carburettor onthe cylinder.

Lift off the air filter holder and carburettorfrom the cylinder.

Model 141BDismantle the cover together with therotary valve and cable bracket.

Model 141BLoosen both screws (A) and lift off thecover together with the rotary valve andcable bracket.

Let the parts remain hanging from thethrottle cable if they are not damaged anddo not need to be replaced.

Dismantle the carburettor from the cylin-der.

Loosen the carburettor screws and lift outthe air filter holder and carburettor.

Remove the fuel hoses from the carburet-tor.

48

3 Fuel system

Pull off the fuel hoses and lift out thecarburettor.

Lift out the carburettor and note how bothfuel hoses are connected to the carburet-tor (rubber hose on the straight nipple).

Design of the carburettorThe carburettor can be divided in threedifferent sub-systems: metering unit, mix-ing venturi and pump unit.

Metering unitThe unit houses the jets and fuel controlfunctions.

Design of the carburettorThe carburettor can be divided in threedifferent sub-systems: metering unit, mix-ing venturi and pump unit.

Metering unitThe unit houses the jets and fuel controlfunctions.

The needle valves and control diaphragmare vital to the operation of the carburet-tor.

Mixing venturiFuel and air are mixed here.

Mixing venturiThe fuel and air are mixed in the correctproportions in this part of the carburettor.

The choke and throttle valve are placedhere.

In the centre of the venturi (narrowestpart of the flow area) is the main jet.

Pump unitPumps fuel from the tank to the carburet-tor.

Pump unitThe pump diaphragm, which pumps fuelfrom the tank to the carburettor's meter-ing unit is located here.

The diaphragm is actuated by the pres-sure variations in the engine's crankcasevia a pulse channel.

If the channel is blocked, e.g. by grease,a gasket turned the wrong way or carbondeposits the pump unit will not work andthe engine cannot be started.

49

3

502 50 38-01

Fuel system

Check the needle valve and lever arm forwear.

Replace damaged parts.

Check the needle valve for wear to the tipand groove for the lever arm.

Check the lever arm for wear to the leverarm groove and wear to the contact pointwith the control diaphragm.

Replace damaged parts.

In the event of leakage dismantle theneedle valve.

Loosen the screw and lift out the leverarm, shaft, needle valve and spring.

With leakage – dismantle the needle valve.

Connect pressure tester 502 50 38-01 tothe fuel pipe nipple.

Lower the carburettor into a bowl of petrolto make it easier to discover any leakage.

Test with 50 kPa.

No leakage is permitted.

Pressure test the metering unit.

Stripping the carburettorGeneralRemove the control diaphragm and checkfor damage.

Replace if necessary.

Stripping the carburettorGeneralRemove the 4 screws holding the controldiaphragm cover and lift off the cover.

Carefully remove the control diaphragmand the gasket.

Check the diaphragm for holes and wearon the pin.

Replace the diaphragm if necessary.

50

3

2

1

Fuel system

Remove the pump diaphragm.

Check the diaphragm for wear.

Remove the screw that holds the coverover the pump membrane.

Lift off the cover, gasket and diaphragm.

Check the diaphragm for wear to thevalve flaps. If the valve flaps are bent thepump will not work satisfactorily.

Also hold it up to a light to see if there areany holes in the material.

Remove the fuel screen. Carefully remove the fuel screen by us-ing, e.g. a needle.

Unscrew the jet needles. Skruva bort munstycksnålarna.

WalbroDismantle the plug (1) and main jet (2).

WalbroDrill a small hole in the plug (1) andcarefully pry it out using a pointed object.

Press out the main jet (2) using a suitablepunch.

NOTE!

Remember how the needles wereplaced. (E.g. the H needle a littleshorter than the L needle).

51

3Fuel system

Reassembling the carburettorBlow out the carburettor housing.

Fit a new plug.

Fit a new main jet.

Reassembling the carburettor● Blow out all the channels in the carbu-

rettor housing.

● Fit a new plug.

Use a suitable punch to attain com-plete tightness.

● Press in a new main jet. This should beflush with the carburettor housing.

Check the plates and spindlesfor wear.Replace damaged parts.

Dismantle the plates and spindles. If theseparts are worn this will cause idling to bedisruptive.

Always replace the plate and spindles atthe same time.

TillotsonDismantle the plugs.

TillotsonDrill a small hole in the plugs and carefullypry them out using a pointed object.

Model Mondo and model 32 have a ver-sion of the previously described carburet-tor with 2 plugs.

Dismantle the plugs.

Model Mondo and model 32 have a ver-sion of the previously described carburet-tor with 2 plugs.

Drill a small hole in the plugs and carefullypry them out using a pointed object.

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3 Fuel system

Fit the plates and spindles. ● Fit the plates and spindles.

Assemble the components in the mixingventuri in the reverse order set out fordismantling.

Assemble the components in the mixingventuri in the reverse order set out fordismantling.

ZamaDesign, function and servicing correspondwith the Walbro carburettor.

ZamaZama has the same design and functionas the Walbro carburettor, which meansthat servicing is also carried out in thesame way.

The lever arm should lie flush with thecarburettor housing’s contact face.

NOTE!

Use Loctite on the plate screws.

Fit the pump unit's components in thereverse order set out for dismantling.

NOTE!

Check that the plate is facing theright way and that it seals correctlyin the closed position.

Use Loctite on the plate screws.

Tips!Any number designation on the plateshould be possible to read from the out-side.

Replace the fuel screen if it is damaged orif it cannot be cleaned.

Place the pump diaphragm closest to thecarburettor housing, then the gasket andcover.

NOTE!The H needle is a little shorter than theL needle.

Check that the lever arm is level with thecarburettor housing (Walbro) or level withthe gasket face (Tillotson).

Too high setting = too much fuel.

Too low setting = too little fuel.

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502 50 38-01

3Fuel system

Dismantle the pump and metering unit. Separate the pump and metering unitfrom the carburettor body.

Pry carefully using a screwdriver.

Dismantling, assemblingModel 122This model has a special Walbro carbu-rettor where the pump and metering unitare placed on the same side as the ven-turi.

Remove the 4 screws and lift off the coverand control diaphragm.

Dismantling, assemblingModel 122This model has a special Walbro carbu-rettor with pump and metering units placedon the same side as the venturi.

Dismantle the control diaphragm.

Place the gasket on the carburettor hous-ing and then the control diaphragm.

Check that the air hole in the cover isopen and screw the cover in position.

Fit the control diaphragm.

GeneralConnect the pressure tester no.502 50 38-01 to the fuel inlet on thecarburettor.

Pump up to a 50 kPa pressure.

Lower the carburettor into a bowl of petrolto discover any leakage.

No leakage is permitted.

GeneralCheck that the carburettor does not leak.

No leakage is permitted at a pressure of50 kPa.

54

502 02 61-02

3

1

Fuel system

Remove the pump diaphragm and in-spect for wear and damage.

Clean or replace the fuel screen (1).

Carefully remove the pump diaphragmand its gasket.

Check the pump diaphragm for wear tothe valve flaps. Also hold it up to a light tocheck the material for holes.

Clean the fuel screen (1). Remove usinga needle for replacement.

Dismantle the lever arm and needle valveto check for wear, replace if necessary.

Loosen the screw and lift off the leverarm, shaft, needle valve and spring.

Check the lever arm and needle valve forwear.

Replace damaged components.

Check for wear to the lever arm on thepoints of contact on the control diaphragmand on the cut-out for the needle valve.

Also check for wear to the needle valve onthe tip and groove for the lever arm.

Replace damaged components.

Replacing the needle valve seat. Press out the needle valve seat for re-placement.

NOTE!

Replace the seat, needle valve andlever arm at the same time.

The needle valve seats should belevel with the carburettor housing.Use a vice with soft jaw guards toavoid damaging the needle valveseat.

55

3

502 50 38-01

Fuel system

Assemble the carburettor and pressuretest it.

Assemble the carburettor in the reverseorder set out for dismantling.

Check that the carburettor does not leakfollowing the procedure described onpage 46.

Dismantle the main jet by prying it out ofthe carburettor housing using a smallscrewdriver.

The carburettor's main jet can be re-moved for replacement.

Use a small screwdriver to pry the mainjet out of the carburettor housing.

Take care not to lose the small O-ringunder the main jet.

NOTE!

Do not dismantle the plastic pipein the throttle housing.

The entire throttle vale mechanism can belifted off for replacement once the twoscrews have been removed.

Note which way, e.g. the idling screw isfacing so the new mechanism is posi-tioned correctly.

Replace the entire throttle valve mecha-nism if the throttle pivot is worn.

Assemble the components in the reverseorder set out dismantling.

Check that the lever arm is level with thediaphragm housing.

Too high setting = too much fuel.

Too low setting = too little fuel.

Check the position of the lever arm.

56

1

3

12

L

H

Fuel system

Dismantling, assemblingModel 18HThe carburettor is made by Zama.

It has the same principle design as theTillotson and Walbro carburettors.

Dismantle the primer pump’s bellows andthen the cover over the control diaphragm.

Inspect the control diaphragm and needlevalve in the same way as previously de-scribed.

Dismantling, assemblingModel 18HThe carburettor is made by Zama.

Dismantle the primer pump’s bellows andcover over the control diaphragm.

Dismantle the pump diaphragm and fuelscreen.

Remove the screws holding the coverover the pump diaphragm.

Lift off the cover, pump diaphragm andgasket.

Check the diaphragm (1) in the same wayas previously described.

Carefully remove the fuel screen (2) using,e.g. a needle.

Unscrew the jet needles. Unscrew the jet needles.

The plastic sleeves must first be removedusing a screwdriver on carburettors withmovement limiters.

Press out the main jet for possible re-placement using a suitable punch.

The main jet can be pressed out for pos-sible replacement using a suitable punch.

NOTE!

Notice how the needles are posi-tioned.

(For example, the H-needle is alittle shorter than the L needle).

NOTE!

When the new jet is fitted it mustnot be pressed in further than sothat edge (1) on the jet lies flushwith the carburettor housing.

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3

1

2

Fuel system

AssemblyModel 265Fit the screwdriver guide over the jetscrews and slide the carburettor in posi-tion over the studs.

AssemblyModel 265Before the carburettor can be fitted on thecylinder the screwdriver guide should beplaced over the jet screws.

Turn the choke lever to "CHOKE" andclose the choke valve about 1/4. No morethan so the pin (1) on the choke shaft canjust bypass the choke lever's connec-tor (2).

Lift off the cover above the control dia-phragm and carefully remove the non–return valve. Check that it opens andcloses.

Continue to dismantle and assemble thecarburettor in the same way as describedfor model 122 (page 53).

Lift off the cover over the control dia-phragm.

Carefully remove the non-return valveand check that it opens and closes bypressing together the valve’s short sideswith you thumb nail.

Hold the valve against a light to make iteasier to see whether it closes fully.

Continue to dismantle and assemble thecarburettor in the same way as describedfor model 122 (page 53).

Dismantling, assemblingModel 141BRemove the screws and lift off cover withthe pump bellows.

Dismantling, assemblingMod. 141BThis carburettor has a rotary valve in-stead of a throttle valve.

Remove the 4 screws and lift off coverwith the pump bellows.

Assemble the carburettor and pressuretest it.

Wait to fit the movement limiters on the jetneedles.

Assemble the carburettor in the reverseorder as set out for dismantling.

The needle valve lever arm should beadjusted to a level flush with the carburet-tor housing’s contact face.

Wait to fit the movement limiters on the jetneedles.

NOTE!

The control diaphragm and pumpdiaphragm should lie closest to thecarburettor housing!

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3 Fuel system

Check that the pin on the choke shaftgoes in the groove on the choke lever'sconnector.

Connect the fuel pipe and fit the remain-ing components.

Slide the carburettor towards the cylinderat the same time as the choke lever ismoved to the open position. Make surethe pin on the choke shaft goes in thegroove on the choke lever's connector.

Connect the fuel pipe, fit the filter holderand the remaining components.

Model 250Assembly sequence:

1. Secure the intake gasket on the cylinder.

2. Place the radiant heat guard on the crankcase.

3. Place the carburettor in the air filter holder and slide in the carburettor screws.

Do not forget the U-shaped reinforcement plate.

4. Connect the throttle cable and fuel pipe.

5 Place the gasket in position on the carburettor. Check that it faces the right way sothe pulse channel is not blocked.

6. Place the distance piece against the carburettor.

7. Fit the carburettor on the cylinder.

8. Press the carburettor against the cylinder using your thumb and carefully tighten thescrews so that they do not cross thread.

9. Place the remaining two screws in the air filter holder.

10. Tighten all four screws.

Check that the throttle cable seats cor-rectly in the air filter cover.

Fit the choke lever.

Check that the throttle cable seats cor-rectly in the air filter cover.

Apply a little grease to the bearing stud.Position the spring and fit the choke lever.

Check that the spring is capable of mov-ing the valve back.

59

3

B

A

Fuel system

Place the choke lever and carburettor inposition in the air filter cover.

Connect the fuel pipe.

Position the choke lever in the air filtercover and then the carburettor. Checkthat the choke lever enters the groove onthe carburettor's lever arm.

Connect the fuel pipe.

Model 225/232/235Check that the small plastic ring is inposition in the elastic inlet pipe. This pre-vents the pipe from deforming.

Model 225/232/235Check that the plastic ring is in position inthe inlet pipe.

Position the choke lever in the air filterholder and fit the carburettor with theholder on to the cylinder.

Position the choke lever in the air filterholder and slide the carburettor screwsthrough holes and the carburettor housing.

Position the slot in the air filter housing(A) under the screw in the crankcase.

Models 240/245Connect the fuel pipe and throttle cable.

Models 240/245First connect the fuel pipe to the carburet-tor and then fit the throttle cable.

Note the routing of the cable between thecarburettor housing and the idling screwlikewise the connection to the lever armon the carburettor.

Secure the gasket on the carburettor withgrease.

Check that it faces the right way; notblocking the pulse channel.

Now tighten the screws.

Check that the choke lever grips in thegroove (B) on the carburettor's chokelever arm.

NOTE!

The washer should be placed be-tween the crankcase and the airfilter holder.

60

3

A

6

5

4

32

1

Fuel system

Connect the throttle cable and bolt on thecarburettor.

Make sure the cable sits correctly in thecable guides.

Slide the carburettor screws through theair filter holder and the carburettor.

Then connect the throttle cable and boltthe carburettor onto the cylinder. No gas-ket or gasket sealant is needed.

Make sure the cable sits correctly in thecable guides.

Make sure the fuel pipe is not crushedbetween the crankcase and air filter holder.

Models 322, 3251. First assemble the fuel hoses on the

carburettor.

Model 32Position the carburettor gasket and con-nect the fuel pipe and throttle cable.

Model 32Position the carburettor gasket on thecrankcase.

Connect the fuel pipe and throttle cable tothe carburettor.

NOTE!

The air filter holder should be in-serted into the guide (A) on thecrankcase.

2. Keep the air filter holder (1) in positionon the carburettor.

3. Slide in the carburettor screws (2).

4. Position the gasket (3) and screw to-gether the entire carburettor assemblyagainst the distance piece (4). Tightenthe carburettor screws crosswise.

NOTE!

The hose, with the fuel filter in thetank, should be fitted on the carbu-rettor’s inlet side (pump chamber).

5. Connect the throttle cable to the leverarm on the carburettor.

Make sure the cable enters the cor-rect slot in the clutch cover and in theguide on the air filter holder (6).

Assemble the remaining parts in the re-verse order as set out for dismantling.

NOTE!

Do not forget the screw (5) that holdsthe air filter holder against the dis-tance piece.

NOTE!

Connect the cable in the right holeon the lever arm and ensure it pullscorrectly.

61

3Fuel system

Position the carburettor and cover plate.

Fit the choke valve and tighten the carbu-rettor screws.

Align the carburettor over the securingholes and position the cover plate.

Fit the carburettor screws, bear in mindthe position of the curved washer andstop shoulder by choke valve. Turn thechoke valve the right way!

Tighten the carburettor screws and fit theair filter.

Model MondoConnect the throttle cable.

Connect the fuel pipes.

Position the carburettor.

Model Mondo● Connect the throttle cable to the throt-

tle valve's lever arm.

● Connect the fuel pipes.

Hold the carburettor in place and fit the airfilter holder and support plate with thelower screw.

Hold the carburettor in place.

Position the air filter holder with its sup-port plate on the carburettor.

Guide the holder and carburettor by us-ing the lower screw.

Check that the gasket has not moved.

Fit the choke valve. Place the choke valve in the air filterholder and tighten the screw.

Check that the stop sleeve is seated cor-rectly in the hole in the valve and that itcan be opened and closed without jam-ming.

NOTE!

The curved washer should restagainst the valve.

Check that the intake gasket is placedcorrectly and position the carburettor.

Watch the routing of the throttle cable.

NOTE!

Select the right hole. See photo.

Make sure the fuel pipes are notmixed up. See photo on page 39.

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3

A

A

B

A

Fuel system

Fit the filter support (A), air filter and filtercover.

Clean/replace the air filter if necessary.

Fit the filter support (A). This must beused to prevent particles from the air filterbeing drawn into the carburettor.

Now fit the air filter (clean first in tepid,soapy water if necessary) and air filtercover.

Model 18HConnect the fuel hoses.

Model 18HConnect the fuel hoses on the carburet-tor.

The thin hose (A) is connected to thenipple on the carburettor body (pumpdiaphragm).

Connect the throttle cable.

Tighten the air filter holder.

Clean or replace the air filter.

Connect the throttle cable (A) to the throt-tle valve’s lever arm.

Secure the cable guide (B) on the dis-tance piece.

Tighten the air filter holder.

Do not forget the gasket between thecarburettor and the distance piece!

Clean or replace the air filter before as-sembly.

Clean in tepid soapy water.

Fit the air filter cover.

Model 141BFit the distance piece on the cylinder.

Model 141BPay special attention that the distancepieces and gaskets face the right way anddo not block the impulse channel whenfitted on the cylinder.

Secure the distance piece closest to thecarburettor with a little grease. This facili-tates carburettor assembly.

63

3

A

L

L

H

H

Fuel system

Turn the carburettor so that the recessedsealing ring (A) comes against the airfilter holder.

Tighten the carburettor and air filter holderagainst the cylinder.

Slide down the rotary valve in the carbu-rettor and screw on the cover.

Check that the throttle works.

Turn the carburettor so that the recessedsealing ring (A) comes against the airfilter holder.

Place the carburettor screws in the airfilter holder (do not forget the choke valve)and then slide the carburettor on thescrews.

Tighten the carburettor against the cylin-der.

Slide down the rotary valve in the carbu-rettor housing. Tighten the cover andcheck that the throttle is turned easilywhen accelerating and that it rests againstthe idling screw when the throttle is re-leased.

Carburettor settings

! WARNING!

The clutch drum and driveline must, under all circumstances, befitted when testing running the engine after adjusting thecarburettor.

Otherwise there is a risk that the clutch can become detachedand cause serious personal injury.

Function

The carburettor has the task of delivering a combustible air/fuel mixture to the cylinder.

The amount of mixture is controlled by the throttle.

The mixture's composition of petrol and air is controlled by using the adjustable needles”H” and ”L”.

The needles must be correctly adjusted so that the engine can give maximum powerat different speed, run smoothly when idling and react quickly when accelerating.

The carburettor setting can vary a little depending on the humidity, temperature and airpressure.

L = Low speed needle

H = High speed needle

T = Idle speed adjuster screw

● The fuel quantity in relation to the air flow permitted by the throttle opening isadjusted by the L and H needles. Turning the needles clockwise gives a leaner fuelmixture (less fuel) and turning them anticlockwise gives a richer fuel mixture (morefuel). A leaner mixture gives higher revs while a richer mixture gives less revs.

● The T-screw regulates the position of the throttle while the engine is idling. Turningthe screw clockwise gives a higher idling speed while turning it anticlockwise givesa lower idling speed.

Basic setting

The carburettor is set to its basic setting when test run at the factory. The basic setting is”richer” than the optimal setting (the max speed is 600–800 rpm under the recommendedmax. speed) and should be kept during the engine's first working hours. Thereafter thecarburettor should be finely adjusted. The basic setting can vary between:

H = 1 to 1 1/4 turns (model 235 P: 3/4 – 1 turn, Mondo + Mega + Max,18 H: 2 turns, 322, 325: 2 1/2 turns)

L = 1 to 1 1/4 turns (model 235 P: 3/4 – 1 turn, Mondo + Mega + Max, 18H: 2 turns)

Basic setting model 235 P

The pruner's engine can not be revved to the max speed as the cutting head's bladesgo against the stop and the engine slows. Consequently, the engine revs at max underload. The high speed needle H should not be changed from the basic settings (3/4 – 1turns open). If the muffler smokes heavily, at the same time as the engine 4 strokes agreat deal the setting is too rich. Turn the H needle clockwise until you find the settingthat sounds right.

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502 71 14-01

501 60 02-02

Fuel system

Fine adjustment

Fine adjustment of the carburettor should be carried out after theengine has been ”run-in”.

● The air filter should be clean and the cylinder cover fittedwhen adjustments are made.

First adjust the L needle, then the H needle and finally theidling speed's T-screw.

The following speed recommendations apply:

Idling speed = 2,500 rpm.

Max speedModel During running in After running in

265 10,900 11,500

252, 250 RX (R) 12,900 (11,900) 13,500 (12,500)

240 11,900 12,500

245 11,900 12,500

225 10,500 11,000

232 10,300 10,800

235 10.500 11,000

240 RBD 10,500 11,000

322, 325 12,500 12,500

122 10,800

32 7,000

Mondo 9,000

Mega / Max 9,000

250PS 11,000 11,500

235 P — —

225 H60 / H75 10,500 11,000

18H 9,500 10,000

132HBV 7,100 7,600

140B / 141B

225HBV 7,700 8,200

Low speed needle L

Find the highest idling speed by slowly turning the low speedneedle clockwise and anticlockwise. When the highest speed hasbeen found, turn the L needle 1/4 turn anticlockwise.

High speed needle H

The high speed needle H affects the engine's power and speed.A too lean H needle setting (H needle screwed in too far) gives toolittle fuel to the engine resulting in damage to the engine.

Run the engine at full throttle for about 10 seconds. The H needleis set correctly when the engine ”splatters” a little.

If the muffler smokes heavily, at the same time as the enginesplatters a great deal the setting is too rich. Turn the H needleclockwise until you find the setting that sounds right.

The max. recommendedspeed must not be exceeded.

When checking the speed ona trimmer no part of the cordshould be extended.

Check the speed using thetachometer 502 71 14-01.

● Carefully screw in (clock-wise) the L and H needlesuntil they bottom. Screwout (anticlockwise) theneedle 1 turn. The carbu-rettor is now set H = 1 andL = 1. Use the specialscrewdriver 501 60 02-02.

● Start the engine and runwarm for 10 minutes.

NOTE!

The max. recommended speed must not be exceeded.

NOTE!If the cutting equipment rotates while idling the T-screwshould be turned anticlockwise until it stops.

NOTE!

A tachometer should always be used to find the optimalsetting.The recommended max. speed must not be exceeded.

Idling speed T-screw

Let the engine idle for about 30 seconds or until the speed hasstabilised. Adjust the idling speed T-screw until the engine idleswithout stopping.

● Turn the screw clockwise if the engine stops.

● Turn the speed anticlockwise to lower the speed.

Correctly adjusted carburettor

A correctly adjusted carburettor means that the engine acceler-ates without hesitation and it 4 strokes a little at full throttle.

● A too lean adjusted L needle can cause starting difficultiesand bad acceleration.

● A too lean adjusted H needle results in lower power, badacceleration and/or damage to the engine.

● A too rich setting of the "L" and "H" needles give accelerationproblems or a too low working speed.

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502 71 14-01531 00 48-63

Fuel system

After replacing the completecarburettor1. Check that the plastic sleeve on the H needle is turned as far

as possible anticlockwise (richest fuel mixture). The sleevesits freely on the needle and can be turned without affectingthe needle's setting.

Do not change the L needle setting. This is adjusted at thefactory and the plastic sleeve is already fixed on the needle.

2. Fit four trimmer cords Ø 3.3 mm on a Trimmy Fix.

(Trimmy Fix M10, 531 00 38-69 for models 225, 232, 322L,322R, 325L, 325L-X, 325R-X. Trimmy Fix M12, 502 13 87-02for model 235).

Maybe the hole needs to be enlarged a little to make fitting thetrimmer cords easier.

(Does not apply to Models 225H60/H75).

3. Cut the trimmer cord to the right length (measure the lengthto the edge of the Trimmy Fix).

Model 225: 145 mm

Model 232: 155 mm

Model 235: 170 mm

Models 322L/R, 325L/L-X/R-X: 142 mm

Montera Trimmy Fix på maskinen.

Model 322C must be run with Trimmy Hit VI and its standard cord(Ø 2.0 mm). Cut off the cord ends so that they are 146 mm long.

(Does not apply to model 225H60/H75 and 18H).

6. Run the engine warm for 2–3 minutes.7. Check that the max speed is still 8400 ± 200 rpm. Adjust the

H needle if necessary.8. Check that the plastic sleeve on the H needle is still turned as

far as possible anticlockwise (richest fuel mixture).9. Press in the plastic sleeve using a punch (Ø 5 mm).

The basic setting of the carburettor is now complete. Further fineadjustment, within the limits that the plastic sleeves on the needlespermit, can be necessary.

Deviations for models 225H60/H75, 18H:5A. Adjust the H needle until the max speed is reached.

Then turn the needle anticlockwise until the speed drops by500 rpm.

6A. Run the engine warm at full throttle for 2–3 min.7A. Check the idling speed and that the engine reacts quickly

when accelerating.7B. Adjust the H needle so that the max. speed is reached. Then turn

the needle anticlockwise until the speed drops by 500 rpm.

After replacing only the H needle1. Turn the L needle as far as possible anticlockwise (richest fuel

mixture).2. Remove the plastic sleeve on the H needle and unscrew the

needle.3. Carefully screw the new H-needle to the bottom and then

loosen it 1/2 turn. On model 322/325 the needle should beloosened approx. 2 1/2 turns.

4. Press a new plastic sleeve on the H needle down to the firststop. The sleeve can now be turned without turning the needle.

5. Turn the plastic sleeve as far as possible anticlockwise (richestfuel mixture) without turning the needle.

6. Fit four trimmer cords Ø 3.3 mm on a Trimmy Fix.(Trimmy Fix M10, 531 00 38-69 for models 225, 232, 322L,322R, 325L, 325L-X, 325R-X. Trimmy Fix M12, 502 13 87-02for model 235).Maybe the hole needs to be enlarged a little to make fitting thetrimmer cords easier.(Does not apply to model 225H60/H75 and 18H).

7. Cut the trimmer cord to the right length (measure the length tothe edge of the Trimmy Fix).Model 225: 145 mm Model 232: 155 mmModel 235: 170 mm Models 322L/R, 325L/L-X/R-X: 142 mmFit the Trimmy Fix on the machine.Model 322C must be run with Trimmy Hit VI and its standard cord(Ø 2.0 mm). Cut off the cord ends so that they are 146 mm long.(Does not apply to model 225H60/H75 and 18H).

Carburettors in E-TECH and CARB-EPA designs(CARB-EPA only applies to USA)On these types of carburettor the H and L needles can be adjusted within extremelytight limits, to among others, comply with the stringent demands with regard to thehydrocarbon and nitrogen oxide content in the exhaust fumes.

The carburettor needles on these carburettors are fitted with plastic sleeves withmovement limiters

To carry out adjustment when replacing needles or the entire carburettor the enginemust be under load. This is achieved by fitting a Trimmy Fix with the specified length anddiameter of trimmer cord. Consequently, the stated speed will be much lower that with"normal" carburettor adjustment when the motor may run freely.

After replacing the needles or the entire carburettor on a CARB-EPA approved engine,adjustment must be carried out according to the instructions below.

The combiguard or trim guard must be fitted when adjusting the H-needle.

NOTE!

The spray guard must be removed from model 235.Exercise care when the trimmer cord is rotating.

4. Start the engine. Adjust the idling speed T screw if necessary.

5. Use screwdriver 531 00 48-63 to adjust the H needle. Theblade is 2 mm wide and goes through the plastic sleeve andonly adjusts the needle.

Adjust the H needle so that the max. speed 8400 ± 200 rpm is set.

Use the tachometer 502 71 14-01 to check the speed.

(Does not apply to model 225H60/H75 and 18H).

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531 00 48-63 502 71 14-01

531 00 48-63 502 71 14-01

Fuel system

10. Run the engine warm for 2–3 minutes.

11. Check that the max speed is still 8400 ± 200 rpm. Adjust theH needle if necessary.

12. Check that the plastic sleeve on the H needle is still turned asfar as possible anticlockwise (richest fuel mixture).

13. Press in the plastic sleeve using a punch (Ø 5 mm).

The basic setting of the carburettor is now complete. Further fineadjustment, within the limits that the plastic sleeves on theneedles permit, can be necessary.

Deviations for models 225H60/H75, 18H:9A. Adjust the H needle until the max speed is reached.

Then turn the needle anticlockwise until the speed drops by500 rpm.

10A.Run the engine warm at full throttle for 2–3 min.

11A.Check the idling speed and that the engine reacts quicklywhen accelerating.

11B. Adjust the H needle so that the max. speed is reached. Thenturn the needle anticlockwise until the speed drops by 500 rpm.

8. Press the plastic sleeve on the L needle using a punch(Ø 5 mm).

Now turn the L needle as far as possible anticlockwise (richestfuel mixture).

9. Turn the plastic sleeve on the H needle as far as possibleanticlockwise (richest fuel mixture).

10. Fit four trimmer cords Ø 3.3 mm on a Trimmy Fix.

(Trimmy Fix M10, 531 00 38-69 for models 225, 232, 322L,322R, 325L, 325L-X, 325R-X. Trimmy Fix M12, 502 13 87-02for model 235).

Maybe the hole needs to be enlarged a little to make fitting thetrimmer cords easier.

(Does not apply to model 225H60/H75 and 18H).

11. Cut the trimmer cord to the right length (measure the length tothe edge of the Trimmy Fix).

Model 225: 145 mm Model 232: 155 mm

Model 235: 170 mm

Model 322L/R, 325L/L-X/R-X: 142 mm

Fit the Trimmy Fix on the machine.

Model 322C must be run with Trimmy Hit VI and its standard cord(Ø 2.0 mm). Cut off the cord ends so that they are 146 mm long.(Does not apply to model 225H60/H75 and 18H).

After replacing the H and L needles1. Remove the plastic sleeves from both needles and screw out

the needles.

2. Carefully screw the new needles in until they bottom.

Now screw out the L-needle 2 turns. On models 322/325 theneedle should be screwed out approx. 1 turn.

Now screw out the H-needle 1/2 turns. On models 322/325 theneedle should be screwed out approx. 2 1/2 turns.

3. Press the new plastic sleeves on the needles until the first stop.The sleeves can still be turned without the needles turning.

4. Turn the plastic sleeve on the L needle as far as possibleclockwise (leanest fuel mixture).

5. Start the engine and let it idle.

6. Use the screwdriver 531 00 48-63 to adjust the L needle. Theblade is 2 mm wide and goes through the plastic sleeve andonly adjusts the needle.

Adjust the L needle so that the highest idling speed is obtained.

Use the tachometer 502 71 14-01 to check the speed.

7. Check that the plastic sleeve on the L needle is still turned asfar as possible clockwise (leanest fuel mixture).

12. Start the engine. Adjust the idling speed T screw if necessary.

13. Use screwdriver 531 00 48-63 to adjust the H needle. Theblade is 2 mm wide and goes through the plastic sleeve andonly adjusts the needle.

Adjust the H needle so that the max. speed 8400 ± 200 rpmis set.

Use the tachometer 502 71 14-01 to check the speed.

(Does not apply to model 225H60/H75).

14. Run the engine warm for 2–3 minutes.

15. Check that the max speed is still 8400 ± 200 rpm. Adjust theH needle if necessary.

16. Check that the plastic sleeve on the H needle is still turnedanticlockwise as far as possible (richest fuel mixture).

17. Press in the plastic sleeve using a punch (Ø 5 mm).

The basic setting of the carburettor is now complete. Further fineadjustment, within the limits that the plastic sleeves on theneedles permit, can be necessary.

Deviations for models 225H60/H75, 18H:13A.Adjust the H needle until the max speed is reached.

Then turn the needle anticlockwise until the speed drops by500 rpm.

14A.Run the engine warm at full throttle for 2–3 min.

15A.Check the idling speed and that the engine reacts quicklywhen accelerating.

15B. Adjust the H needle so that the max. speed is reached. Thenturn the needle anticlockwise until the speed drops by 500 rpm.

NOTE!

The spray guard must be removed from model 235.Exercise care when the trimmer cord is rotating.

8. Start the engine. Adjust the idling speed T screw if necessary.

9. Use screwdriver 531 00 48-63 to adjust the H needle. Theblade is 2 mm wide and goes through the plastic sleeve andonly adjusts the needle.

Adjust the H needle so that the max. speed 8400 ± 200 rpmis set.

Use the tachometer 502 71 14-01 to check the speed.(Does not apply to model 225H60/H75 and 18H).

NOTE!

The spray guard must be removed from model 235.Exercise care when the trimmer cord is rotating.

67

3

502 71 14-01531 00 48-63

A

B

A

Fuel system

Replacing only the L needle1. Turn the H needle as far as possible clockwise (leanest fuel

mixture).

2. Remove the plastic sleeve on the L needle and unscrew theneedle.

3. Carefully screw the new L-needle to the bottom and thenloosen it 2 turns. On models 322/325 unscrew the needle 1turn.

4. Press a new plastic sleeve on the L needle down to the firststop. The sleeve can now be turned without turning theneedle.

5. Turn the plastic sleeve as far as possible clockwise (leanestfuel mixture).

6. Start the engine and let it idle.

7. Use the screwdriver 531 00 48-63 to adjust the L needle. Theblade is 2 mm wide and goes through the plastic sleeve andonly adjusts the needle.

Adjust the L needle so that the highest idling speed isobtained.

Use the tachometer 502 71 14-01 to check the speed.

8. Check that the plastic sleeve on the L needle is still turned asfar as possible clockwise (leanest fuel mixture).

9. Press the plastic sleeve on the L needle using a punch(Ø 5 mm).

The basic setting of the carburettor is now complete. Further fineadjustment, within the limits that the plastic sleeves on theneedles permit, can be necessary.

Model 141BOnly the idling speed can be adjusted onthis model.

The idling speed should be approx. 2,500rpm.

Model 141BThe carburettor on this model has noadjustable needles.

Only the idling speed can be adjustedwith screw (A).

The right speed is approx. 2,500 rpm

Adjust the idling speed when the engineis warm and has a clean air filter.

Check that the throttle cable has 0.5 – 1mm of play.

When the throttle is in the idling positionthe throttle cable must have 0.5 – 1 mm ofplay.

Adjust the play by first loosening bothlocking nuts (A) and then turning theadjuster screw (B). The play is increasedwhen the screw is screwed inwards anddecreases when screwed outwards.

Tighten the locking nuts against eachother after adjusting.

68

A

B

3

C

D

C

Fuel system

ThrottleModel 265Dismantle the throttle cable.

Lift off the throttle.

ThrottleModel 265Loosen the locking screw (A) and pull outthe throttle cable.

Remove the three screws that hold thethrottle on the handle and lift off the gripand the two clamp halves.

Loosen the locking screw (B) and dis-mantle the throttle.

Loosen the locking screw (B).

The return spring (C) is now accessibleand the throttle control (D) with its shaftcan be pulled from the throttle.

Press out the bearing pin from the throttlelock using a punch.

Replace damaged parts and reassemblein the reverse order set out for disman-tling.

Fold back the rubber handle and pressout the bearing pin using a punch.

The spring and throttle lock are now ac-cessible for replacement.

Reassembly of the throttle takes place inthe reverse order set out for dismantling.

Reassembly of the throttle takes place inthe reverse order set out for dismantling.

Tension the spring (C) about 1/4 – 1/2turn.

69

3Fuel system

A

B

Press out the bearing pin from the throttlelock using a punch.

Replace damaged parts and reassemblein the reverse order set out for disman-tling.

Fold back the rubber handle and pressout the bearing pin using a punch.

The spring and throttle lock are now ac-cessible for replacement.

Dismantle the short circuit cable's con-tact strips for inspection and possiblereplacement.

Lift out the short circuit cable's contactstrips using flat nose pliers.

Check the contact surface on the stripsreplace or clean them if they are corrodedor burnt.

Loosen the screw (A) and lift out thethrottle cable's connection piece (B) andthe return spring.

Loosen the screw (A) and lift out theconnection piece (B) and the return spring.

Model 250Remove the screw and cover.

Model 250Fold down the handle for better accessi-bility.

Remove the screw and cover over thethrottle cable's and the short circuit ca-ble's connection in the handle.

The throttle's shaft can now be removedfor replacement.

NOTE!

There is some tension on thespring.

70

A

Fuel system3

B

Reassembly of the throttle takes place inthe reverse order set out for dismantling.

Reassembly of the throttle takes place inthe reverse order set out for dismantling.

Lubricate with a little grease, preferablycold resistant.

● Lubricate the throttle control shaft with a little grease and slide it in the bearinghousing.

● Position the return spring and check that it enters the hole in the bearing housing.

● Place the throttle cable's connection piece in position and also check here that thespring enters the hole.

● Connect the throttle cable.

● Press the throttle cable's connection piece down over the shaft.

● Make sure the throttle is in the idling position.

● Tension the throttle cable by turning the connection piece to the position when thethrottle valve just starts to move.

● Tighten the screw and check that the throttle also functions as intended in the stopposition.

Models 225HBV, 225R, 232R,235R, 245R, 250RDismantle the throttle from the handleand remove the screws that hold togetherthe two halves of the throttle grip.

Carefully separate the two halves.

Replace any damaged parts.

Check when reassembling that the guidepin (A) enters the hole in the throttle lock(B), and that the lock functions withoutjamming when both throttle halves havebeen screwed together.

71

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le3Fuel system

72

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Fuel system

73

3Fuel system

Models 225 L, E, 232 LRemove the screws.

Disconnect the cables from the stopswitch.

Models 225 L, E, 232 LRemove both the screws that hold thethrottle halves together.

Fold back the right half and disconnectthe cables from the stop switch.

Unhook the throttle cable from the carbu-rettor.

Lift up the plastic guide and unhook thethrottle cable from the carburettor.

Inspect the different parts with regard towear and damage.

Replace damaged components.

Fold back the left half of the throttle.

The different parts are now easily acces-sible for service or replacement.

Reassemble the throttle in the reverseorder set out for dismantling.

Check that it functions, especially thethrottle lock.

Reassemble the throttle in the reverseorder set out for dismantling.

Note the following:● Check that the throttle cable and short

circuit cable are not crushed.● The cable rail should be under the

throttle control.● The pin in the throttle control's left half

goes in the hole on the under side ofthe shaft.

74

3

A

C C

C

B

BA

Fuel system

Models 322, 325Separate the engine body and the clutchcover.

Models 322, 325We recommend that the throttle is dis-mantled from the engine and shaft inorder to efficiently carry out service andrepair work.

Separate the engine body and the clutchcover (see chapter "Ignition system").

Pull away the shaft with the throttle fromthe clutch cover.

Remove the throttle from the shaft.

Remove both screws (A) (one on eachside).

Loosen the screws (B) and pull off theshaft with the throttle from the clutchcover.

Loosen the 3 front screws (C) (approx. 2turns) holding the throttle halves and pullthe throttle off of the shaft.

Remove the screws holding the throttletogether and carefully separate the halves.

Note how the different parts are fitted.Pay special attention to which way thereturn spring (A) faces.

The stop contact can be pried back usinga small screwdriver if it needs to be re-placed.

75

3

A

A

Fuel system

A

Remove the throttle cable.

The shaft and engine body must be sepa-rated to replace the throttle.

Remove the throttle cable, replace if nec-essary.

The shaft and engine body must be sepa-rated if the entire throttle is to be re-placed.

Loosen the screw/screws (A) and removethe short circuit cable.

Remove the handle. It is easier if soap isused as a slip agent.

Models 122/32/MondoRemove the screw and slide the throttleforward until the throttle cable is access-ible.

Models 122/32/MondoRemove the screw that holds throttle onthe shaft and slide the throttle forwarduntil the throttle cable is accessible.

Assembly of the throttle is done in thereverse order as set out for dismantling.

Position the parts in the left-hand throttlehalf.

Ensure the return spring (A) is facing theright way.

Check that the throttle cable and theshort-circuit cable are pressed correctlydown in their channels so that they arenot pinched when the two throttle halvesare screwed together.

Do not forget to put the vibration element(B) in position before the throttle halvesare put together. Lubricate the vibrationelement with soapy water. This facilitatesfitting the throttle on the shaft.

Fit together the throttle halves using the 5screws, but do not tighten them fully be-fore the throttle has been positioned onthe shaft.

Assemble the remaining parts in the re-verse order as set out for dismantling.

B

76

3

A

Fuel system

Models 225 H 60, 225 H 75Remove the locking plate and pull out therear handle from the handlebars.

Models 225 H 60, 225 H 75Remove the locking plate by prising itupwards using two screwdrivers.

Pull out the rear handle from the handle-bars.

Separate the two handle halves and in-spect the different components for wear,replace if necessary.

Reassemble in the reverse order set outfor dismantling.

Remove the screws and carefully sepa-rate the two handle halves. All compo-nents are now easily accessible for pos-sible replacement.

Reassemble in the reverse order set outfor dismantling.

Models 250PS, 235 PRemove the screws and separate thehandle halves.

Models 250PS, 235 PRemove all the screws and carefully sepa-rate the handle halves.

Inspect all parts with regard to wear anddamage. Replace damaged parts.

Reassemble in the reverse order set outfor dismantling.

NOTE!

Ensure that the throttle cableenters the cut-out (A) correctlyso that it is not crushed when theother handle half is fitted.Lubricate the O-ring with grease.

NOTE!

Check that the short circuit cablesand throttle cable are not crushed.

The short circuit cables should berouted outside of the handleexcept at the rear and frontsections.

77

3Fuel system

Inspect and replace worn or damagedparts.

Assemble in the reverse order as set outfor dismantling.

Inspect and replace worn or damagedparts.

Assemble in the reverse order as set outfor dismantling.

Model 18HRemove the screws and note how theywere placed, as they are of differentlengths.

Remove the handle half.

Model 18HRemove the screws and lift off the handlehalf.

Inspect all parts with regard to wear anddamage. Replace damaged parts.

Reassemble in the reverse order set outfor dismantling.

Models 232 RBD, 240 RBDRemove the screws and separate thehandle halves.

Models 232 RBD, 240 RBDRemove the screws and separate thehandle halves.

NOTE!

The lever arm for the throttle cabledoes not need to be dismantled.

NOTE!

Check that the short circuit cableis under the throttle cable'scasing to prevent it from beingcrushed.

78

3 Fuel system

NOTE!Check that the fuel hose is notpinched and that the stop contactsits correctly.

Fit the throttle cable.

NOTE!Check that the fuel hose is notpinched and that the stop contactsits correctly.

Fit the throttle cable.

Model 141BRemove the screws and separate thehandle halves.

Model 141BRemove the screws and separate thehandle halves.

Worn or damaged parts can be easilyreplaced once the right-hand handle halfhas been removed.

Check when assembling that the short-circuit cable is not pinched between thetwo handle halves.

NOTE!

The screw for angling the handledoes not need to be loosened orremoved.

79

Mondo

122L

Mondo Max

225L/LD

232L

Mondo Mega

225R/RD

232R / 235 R

322

325

240R

245R

250R

245RX

250RX

252RX

265RX

240RBD

235P

250PS

225E

18H

225H60/75

140B

141B

132HBV

225BV/225HBV

3

3,000 9,000 Walbro H = 2 0.48WT 380 L = 2

3,000 10,800 Walbro – 0.40WYL –

3,000 9,000 Walbro H = 2 0.48WT 380 L = 2

2,700 11,000 – Walbro WT 235 H = 1 – 1 1/4 0.5012,000 Walbro WT 270 L = 1 – 1 1/4

2,700 11,000– Walbro WT 235 H = 1 – 1 1/4 0.5012,000 Walbro WT 270 L = 1 – 1 1/4

3,000 9,000 Walbro H = 2 0.46WT 380 L = 2

2,700 11,000– Walbro WT 235 H = 1 – 1 1/4 0.5012,000 Walbro WT 270 L = 1 – 1 1/4

2,700 11,000– Walbro WT 235 H = 1 – 1 1/4 0.5012,000 Walbro WT 270 L = 1 – 1 1/4

2,500 12,500 Zama H = 2 0.50EL 11 L = 1

2,500 12,500 Zama H = 2 0.50EL 11 L = 1

2,700 12,500 Walbro H = 1 – 1 1/4 0.80WT 99 L = 1 – 1 1/4

2,700 12,500 Walbro H = 1 – 1 1/4 0.80WT 99 L = 1 – 1 1/4

2,700 12,500 Walbro HDA 86B H = 1 – 1 1/4 0.80Walbro HDA 142 L = 1 – 1 1/4

2,700 12,500 Walbro H = 1 – 1 1/4 0.80WT 99 L = 1 – 1 1/4

2,700 13,500 Walbro HDA 86B H = 1 – 1 1/4 0.80Walbro HDA 142 L = 1 – 1 1/4

2,700 14,000 Walbro H = 1 – 1 1/4 0.80HDA 142 L = 1 – 1 1/4

2,250 11,500 Tillotson H = 1 – 1 1/4 1.00HS 121A L = 1 – 1 1/4

2,700 11,000– Walbro WT 235 H = 1 – 1 1/4 0.6012,000 Walbro WT 270 L = 1 – 1 1/4

2,700 – Walbro WT 235 H = 3/4 – 1 0.50Walbro WT 270 L = 3/4 – 1

2,500 11,500 Walbro HDA 86B H = 1 – 1 1/4 0.90Walbro HDA 142 L = 1 – 1 1/4

2,700 11,000– Walbro H = 1 – 1 1/4 0.5012,000 WT 270 L = 1 – 1 1/4

3,000 10,000 Walbro WT 379 H = 2 0.21Zama CIU-W4 L = 2

2,700 11,000– Walbro WT 406 H = 1 – 1 1/4 0.4012,000 Walbro WT 421 L = 1 – 1 1/4

2,500 Walbro HDA 110A H = 1 2.0L = 1

2,500 Walbro WYK – 2.0

2,500 7,600 Walbro 0.60WT 141

2,500 8,200 Walbro WT 235 H = 1 – 1 1/4 0.40Walbro WT 270 L = 1 – 1 1/4

Fuel system

Technical data

Model Idling speed Max. speed Carburettor type Tank volumerpm rpm ◊ type setting * fuel, l

* Only basic setting. Applies to carburettor needles without plastic caps fitted.◊ Do not exceed the stated max speed. Risk of engine damage. The figures apply to a run-in engine Reduce the speed by 600–700 rpm for an engine that has not been run-in.

80

81

4.Centrifugal clutch

ContentsClutch and clutch drumModel 265 ________________________________ 82

Model 250 ________________________________ 85

Model 250PS _____________________________ 89

Models 240/245 ___________________________ 90

Models 225R/232R _________________________ 92

Models 225L/232L _________________________ 92

Models 225/232/235 ________________________ 92

Models 225 H60/H75 _______________________ 93

Models 225 AI15, 225 AI25 __________________ 94

Model 235 ________________________________ 95

Model 240RBD ____________________________ 97

Models 322, 325 ___________________________ 98

Model 122 _______________________________ 100

Models 32, Mondo ________________________ 102

Model 18H ______________________________ 104

Technical data ____________________________ 106

82

4

502 54 15-01

A

Centrifugal clutch

Some slipping occurs between the clutch andthe clutch drum when accelerating as well as inthe reversed situation when the cutting equip-ment jams. Thereby preventing abnormal loadchanges on the crankshaft.The engagement speed has been carefully testedso that the engine can idle without the cuttingequipment's drive shaft rotating.

The centrifugal clutch has the task of transferringthe power from the engine to the cutting equipment.As the name implies, it works according to a cen-trifugal principle.This means the clutch's friction shoes are thrownoutwards towards the clutch drum at a certainengine speed. When the friction against the drum issufficiently great it drives the drive shaft at thesame speed as the engine.

Clutch model 265DismantlingRemove the cylinder cover and the earthcable (A).

Clutch model 265DismantlingRemove the cylinder cover and the earthcable (A).

Undo the screws and lift off the clutchcover complete with the shaft.

Undo the 4 bolts that hold the clutch coveron the engine body.

Lift off the complete unit with shaft andclutch cover.

Dismantle the centrifugal clutch from thecrankshaft.

Replace the spark plug with the pistonstop no. 504 91 06-05. Unscrew the clutchfrom the crankshaft.

NOTE!

Left-hand thread!

83

4

502 50 49-01

502 50 49-01

min

. 1 m

m

Centrifugal clutch

Fit the remaining clutch shoe. Fit the remaining clutch shoe. Use theassembly pliers no. 502 50 49-01 and ascrewdriver.

AssemblyPlace two clutch shoes and the spring onthe clutch hub.

AssemblyPlace two clutch shoes and the spring onthe clutch hub.

Clean and inspect the clutch hub's armsand the clutch shoes with regard to wear.

There must be at least 1 mm of materialremaining on the most worn area on theclutch shoes.

All shoes must be replaced at the sametime.

Clean and inspect the clutch parts withregard to damage and wear.

Remove the clutch springs. Remove the clutch springs using pliersno. 502 50 49-01 and a screwdriver.

NOTE!

The spring's connection pointshould come in the centre of oneof the hub's arms.

84

4

A

Max

. 80.

0

Centrifugal clutch

Fit the clutch on the crankshaft. Fit the clutch on the crankshaft.

Do not forget the thick spacer inside theclutch.

Tighten the clutch.

Clutch drumModel 265Check the clutch drum for damage andwear.

Replace the clutch drum if necessary.

Clutch drumModel 265Check the clutch drum for damage andwear.

Measure the inside diameter of the drum.It must not be greater than 80.0 mm.Replace with a new drum if this is thecase.

Dismantle the angle gear so that the endof the drive shaft is accessible.

Lock the clutch drum by inserting a suit-able punch through one of the holes sothat it rests against one of the reinforce-ment ribs in the clutch cover. (See photo).

Undo the drive axle.

It is far easier when fitting the clutch drumto keep the shaft vertical with the clutchdrum facong upwards. This is so thespacer (A) can be centred around thedrive shaft when the clutch drum isscrewed in position.

Fit all other parts in the reverse order setout for dismantling.

NOTE!

Left-hand thread.

Clutch drum can be extremelytight.

85

4

A

C

A

BA

D

Centrifugal clutch

ClutchModel 250Dismantle the cover strip and loosen thescrews (A).

ClutchModel 250Dismantle the following:

Cylinder cover, fuel pipe on the carburet-tor and the cover strip over the throttlecable and short-circuit cable.

Loosen the screws (A).

It is now appropriate to replace the vibra-tion dampers if damaged.

Assembly takes place in the reverse orderset out for dismantling.

Replace the vibration dampers if neces-sary.

Assemble the drive shaft and the remain-ing parts in the reverse order set out fordismantling.

Pull off the clutch cover from the tube andpull out the drive shaft.

Separate the clutch cover and the outersupport so the screws (C) and the stopscrew (D) are accessible.

Loosen the screws and pull off the clutchcover from the tube.

Pull out the drive shaft and check it. If it isbent it must be replaced under all circum-stances.

Drive shaftModel 265Replace the drive shaft if the splines areworn.

Loosen the throttle and remove the screws(A).

Loosen the screw (B).

Drive shaftModel 265Check the drive shaft. If the splines wherethe shaft meshes with the angle gear areworn it should be replaced.

Loosen the throttle from the handle andremove the screws (A).

Loosen the screw (B).

NOTE!

Lubricate the drive shaft usingengine oil before assembling anddo not forget the spacer beforethe shaft is slid into the clutchcover.

The tube should be slid into theclutch cover as far as possible sothat it rests against the bearing.

86

4

B 502 21 58-01

502 21 58-01

504 91 06-05

C

Centrifugal clutch

Remove the screws (B) and (C). Remove the screws (B) and (C). Use toolno. 502 21 58-01 to access the screws(C).

Slide the tank unit forwards on the shaft. Remove the throttle from the handles.

Thread the throttle cable and the shortcircuit cable through the slot in the fueltank.

Slide the tank unit forwards on the shaft.

Remove the screws holding the clutchhousing and separate the shaft from theengine.

Remove the screws holding the clutchhousing on the engine body and pull awaythe entire shaft unit.

Dismantle the clutch nut. Replace the spark plug with piston stopno. 504 91 06-05.

Remove the nut holding the clutch.

87

4

505 26 79-12

504 91 06-05

A

B B

C

Centrifugal clutch

Remove the clutch shoes from the hub. Pry off the clutch shoes from the hubusing a screwdriver. Keep your thumbover the spring as shown in the photo.

Remove the screws (B) and cover wash-ers (C).

Strip the clutch by first removing thescrews (B) and then lift off the coverwashers (C).

Check the clutch shoes for wear. Replaceif necessary.

Check the clutch shoes for wear by meas-uring the distance (A). It must not bebelow 3 mm. If this is the case replaceboth shoes.

Dismantle the clutch from the crank-shaft.

Fit the drift no 505 26 79-12 on the crank-shaft. Do not screw it down fully againstthe clutch.

Lift the engine body by the clutch andapply a few sharp blows with a hammer tothe drift until the clutch becomes loose.

88

4

502 52 16-01

505 38 17-09A

Centrifugal clutch

Check all the parts with regard to wearand damage. Replace faulty parts.

Assemble in the reverse order set out fordismantling.

Compress the spring using a pair of flatnose pliers and insert it in the cut-out inthe clutch shoes.

Clutch drumModel 250Dismantle the clutch housing complete.

Clutch drumModel 250Loosen the screws holding the clutchhousing on the shaft.

Pull off the clutch housing complete withthe clutch drum and the drive shaft fromthe tube.

Undo the clutch drum from the drive shaft. Clamp the drive shaft in a vice and undothe clutch drum.

Remove the circlip and bearing from theclutch housing.

Remove the circlip (A).

Carefully heat the clutch housing (approx.150°C) and press out the bearing usingthe punch no. 505 38 17-09.

NOTE!

Use Loctite on the screws.

Check the clutch drum for wear. The in-side diameter must not exceed 70.0 mm.

NOTE!Use vice guards on the vice so not todamage the drive shaft.

Use tool no. 502 52 16-01 to undo theclutch drum.

89

4

504 91 06-05

502 52 16-01 502 52 14-01

A

B

Centrifugal clutch

Clutch drumModel 250PSDismantle the clutch drum from the hy-draulic unit’s axle.

Clutch drumModel 250PSThe clutch drum is screwed onto thehydraulic unit’s axle.

Dismantle the drum by using the holdingtool 502 52 16-01 and allen key502 52 14-01.

Dismantle the cylinder cover and replacethe spark plug with piston stop no. 504 9106-05.

Remove the clutch nut by turning it anti-clockwise.

Dismantle the clutch from the crankshaftand carry out an inspection and servicingas set out in the instructions for model250.

Remove the clutch nut and dismantle theclutch according to the instructions formodel 250.

ClutchModel 250PSUnscrew the cable clamp (A) and thehose clamp (B).

Turn the hydraulic oil tank clockwise andpull it off from the engine body.

ClutchModel 250PSThe clutch on this model is positionedbetween the engine body and the hy-draulic unit.

1. Unscrew the clamp (A) holding thecontrol cable on the hydraulic oil tank.

2. Loosen the hose clamp (B).

3. Turn the hydraulic oil tank clockwiseand pull it off from the engine body.(Bayonet fitting).

Replace faulty parts and assemble in thereverse order set out for dismantling.

Replace the clutch drum if the inner dia-meter exceeds 70.0 mm.

NOTE!

Turn the allen key clockwise.

The bearing is easier to fit if the clutchhousing is hot (approx. 150°C).

NOTE!

Use Loctite on the clutch drum'sthreads.

90

4

504 91 06-05

Centrifugal clutch

ClutchModels 240/245Separate the engine body and tank unit.

Remove the screws by the clutch housingand remove the shaft.

ClutchModels 240/245Separate the engine body and the tankunit in the same way as described formodel 250.

Remove the screws that hold the clutchhousing against the engine body and liftoff the entire shaft unit.

The clutch can be one of two different designs. Firstly, a three shoe clutch of the sametype as used on model 235. See this model for service measures. This clutch wasintroduced from the following serial numbers:

Model 240R no. 82 00 059, model 245R no. 81 70 180, model 245RX no. 81 60 227.

Secondly, the clutch can be a two shoe model as described below.

Dismantle the clutch using a punch andhammer.

Replace the spark plug with piston stopno 504 91 06-05. Loosen the clutch shoesfrom the crankshaft.

One of the clutch shoes is countersunk togive a purchase for a punch.

Loosen the clutch with a few heavy blowsfrom a hammer.

Remove the leaf springs. Remove the leaf springs by pressing apartthe ends using a pair of circlip pliers.

Press out the tubular pins. Use a suitable punch to remove the tubu-lar pins so that the clutch shoes can bereplaced.

NOTE!

The clutch has a left-hand thread.

91

4

505 38 17-09

Centrifugal clutch

Heat the clutch housing and press out thebearing.

Carefully heat the clutch housing to about150°C and press out the bearing using asuitable punch, e.g. 505 38 17-09.

Replace any damaged parts and assemblein the reverse order set out for dismantling.

The bearing is easier to fit if the clutchhousing is hot (approx. 150°C).

Clutch drumModels 240/245Clamp the drive shaft in a vice and undothe clutch drum. 19 mm spanner.

Use vice guards so that the drive shaft isnot damaged.

Clutch drumModels 240/245Undo the clutch drum.

Loosen the screws that hold the clutchhousing on the tube.

Pull off the clutch housing complete withclutch drum and drive shaft from the tube.

Pull off the clutch housing complete fromthe tube.

Replace any worn or damaged parts andensure the clutch springs are fitted cor-rectly.

Replace any worn or damaged parts.Both clutch shoes should be replaced atthe same time.

NOTE!

Use Loctite on the clutch drum'sthreads.

Do not forget the heat shieldbetween the clutch housing andthe fuel tank.

NOTE!

The clutch drum has a left-handthread.

NOTE!

Check when fitting the clutchsprings that the small pins are oneach side of the clutch shoes.

92

4

504 91 06-05

A

C

B

Centrifugal clutch

ClutchModels 225 R/232 RDismantle the throttle and cable channel.

Models 225 L/232 LRemove the cylinder cover.

Loosen the throttle cable from the carbu-rettor and lift off the cable guide from thecrankcase.

ClutchModels 225 R/232 RDismantle the screw (A) that holds thethrottle and screw (B) on the cable chan-nel.

Loosen the screw (C) and slide the han-dle clamp forwards on the shaft.

Dismantle the cylinder cover.

Models 225 L/232 LRemove the cylinder cover.

Loosen the throttle on the carburettor andlift off the cable guide from the crankcase.

Separate the shaft unit from the enginebody.

Remove the 4 screws that hold the clutchcover on the crankcase.

Now remove the entire shaft unit from theengine body.

Dismantle the clutch from the crankshaft. Replace the spark plug with piston stopno. 504 91 06-05 and dismantle the clutchfrom the crankshaft.

Clutch drumModels 225/232/235Dismantle and assemble the clutch hous-ing, clutch drum and its bearings in thesame way as described for model 250.

Clutch drumModels 225/232/235Loosen the two screws holding the clutchhousing on the shaft.

Pull off the clutch housing complete withclutch drum and drive axle in the shaft.

Dismantle and assemble the clutch drumand its bearings in the same way asdescribed for model 250.

93

4

A

B

A

Centrifugal clutch

Inspect the parts of the clutch with regardto wear and damage.

Inspect the clutch shoes with regard towear on the bearing points and the springsfor crack formation or breakage.

Press out the clutch hub. Strip this type of clutch by pressing outthe clutch hub from the back using yourthumbs.

Dismantle the cutting equipment andclutch from the engine.

Remove the screws that hold the clutchcover on the crankcase.

Lift off the clutch cover complete with thecutting equipment.

Dismantle the clutch from the crankshaftin the same way as described above.

Models 225 H60/H75Separate the engine body and cuttingequipment.

Models 225 H60/H75Separate the engine body and cuttingequipment as follows:

Remove the 4 screws (A) and (B) by thevibration dampers to remove the handleassembly.

! WARNING!

The transport guardshould always be fittedwhen working on thecutting equipment to avoidcuts to the hands.

NOTE!

The shoes and springs shouldalways be replaced in pairs.

Also check the clutch centre'sshoe bearings.

94

4 Centrifugal clutch

Clutch drumModels 225 H60/H75See chapter "Attachments".

ClutchModels 225 AI15, 225 AI25Dismantle the gearbox from the enginebody to access the clutch and clutchdrum.

Also see the previous section for model225/232 concerning servicing the clutch.

Clutch drumModels 225 H60/H75See chapter "Attachments".

ClutchModels 225 AI15, 225 AI25Remove the 6 screws holding the gearhousing on the engine body and lift off thegearbox.

See the previous section for model 225/232 with regard to service and assemblyof the clutch.

Clutch drumModels 225 AI15, 225 AI25Dismantle the screw and lift out the clutchdrum.

Clutch drumModels 225 AI15, 225 AI25The clutch drum can be removed oncethe screw in the centre is unscrewedanticlockwise.

Replace the clutch drum if the inner dia-meter exceeds 64.5 mm.

Tighten the vice carefully and position thecentre.

Tighten the vice sufficiently so that theclutch centre can be positioned.

Fit the clutch on the crankshaft.

Hook on the springs and place the clutchin a vice.

Start to assemble the clutch by hookingthe springs in the clutch shoes.

Then place the clutch in a vice as shown.

NOTE!

Do not forget the large flat washerbetween the clutch and thecrankcase.

The washer acts as a support forthe clutch shoes. If the washer ismissing the shoes can be forcedout of the hub when the engine isrun causing damage to thecrankcase.

NOTE!

The bevel on the clutch shoesshould face upwards.

95

A

B

4

504 91 06-05

Centrifugal clutch

ClutchModel 235Dismantle the throttle. Snap off the pro-tective casing.

ClutchModel 235Dismantle the throttle by removing screw(A).

Snap off the protective casing for thethrottle cable and the short circuit cable.

Loosen screw (B).

Slide the plastic cover complete withhandle forwards on the shaft.

Loosen screw (B) and slide the plasticcover complete with handle forwards onthe shaft so that the screws holding theclutch housing become accessible.

Dismantle the clutch cover and the cylin-der cover.

Remove the four screws holding the clutchcover on the crankcase.

Remove the cylinder cover.

Dismantle the clutch from the crankshaft. Replace the spark plug with piston stopno. 504 91 06-05 and dismantle the clutchfrom the crankshaft.

96

4

min

. 1 m

m

Centrifugal clutch

The spring's connection point should bepositioned in the centre of the slot for theclutch centre's arm.

When assembling the clutch the spring isfirst positioned in one clutch shoe so thatthe spring's connection point comes inthe centre of the slot for the clutch centre'sarm.

Then place the spring in one more shoe.

Check the arms on the clutch centre andthe guide slots for wear.

Check that the arms on the clutch centreare not heavily worn or show signs ofcracking and that the clutch shoe guideslots are not elongated. When replacingall shoes the clutch centre should bereplaced at the same time.

The clutch shoes must have at least 1 mmof material remaining.

Check that the shoes have at least 1 mmof material remaining where they areworn the most.

When replacing all three shoes should bereplaced at the same time to avoid imbal-ance.

Strip the clutch. Strip the clutch by pressing the clutchshoes from behind using your thumbs.

97

4Centrifugal clutch

Position the clutch hub.

Clamp the clutch in a vice and bend outthe spring using a screwdriver so that thethird clutch shoe can be fitted.

Now position the clutch hub and thenclamp the clutch in a vice.

Use a screwdriver to bend out the springso that the third clutch shoe can bepressed into place.

Use a pair of flat nose pliers to locate thespring if necessary.

On model 235 P the clutch is accessiblewhen the hydraulic unit has been disman-tled.

Dismantle the clutch from the crankshaft.

On model 235 P the clutch is accessiblewhen the hydraulic unit has been disman-tled.

Remove the 4 screws and lift off thehydraulic unit.

Dismantle the clutch from the crankshaftin the same way as set out for models225/232.

The clutch has the same design as models225/232.

Clutch drumModels 235, 235PSee chapter "Hydraulic unit".

Clutch drumModels 235, 235PSee chapter "Hydraulic unit".

ClutchModels 240 RBDDismantle the cover plate and the clutchhousing.

Unscrew the clutch from the crankshaft.

ClutchModels 240 RBDRemove the 4 screws holding the coverplate and clutch housing on the crankcase.

Dismantle the clutch from the crankshaftas explained for models 225/232.

The clutch has the same design as models225/232.

NOTE!

Do not forget the large flat washerbetween the clutch and thecrankcase.

The washer acts as a support forthe shoes, and if missing theshoes can be forced out of thehub when the engine is runcausing damage to the crankcase.

98

4 Centrifugal clutch

Connect the clutch shoes together withthe spring.

Twist apart the clutch and inspect thedifferent parts with regard to wear ordamage.

Twist apart the clutch.

Inspect the different parts with regard towear or damage.

Pay special attention to the ends of thesprings, which in addition to wear, canalso show signs of cracking.

ClutchModels 322, 325Dismantle the clutch by following the in-structions in the chapter "Ignition sys-tem".

ClutchModels 322, 325The centrifugal clutch is bolted to theflywheel.

Follow the detailed instructions in thechapter "Ignition system" when the clutchis to be dismantled.

Clutch drumModel 240 RBDLoosen the screws so that the drive shaftcan be pulled out of the clutch housing.

Clutch drumModel 240 RBDLoosen the screws so that the drive shaftcan be pulled out of the clutch housing.

Dismantle and assemble the clutch hous-ing and its parts in the same way asdescribed for model 250.

NOTE!

The screw that holds the driveshaft in place should be screwedin the clutch housing from thethreaded side (not through thefree hole) so that the drive shaftcan be turned freely in the clutchhousing.

Bolt the clutch on the flywheel. Do notforget the washers between the flywheeland the clutch shoes.

NOTE!

Both clutch shoes should bereplaced even if only one of themis showing signs of heavy wear.This is to avoid engine vibrationcaused by imbalance in the clutch.

99

502 52 16-01

4Centrifugal clutch

Clutch drumModels 322/325Separate the shaft from the clutch cover.

Dismantle the clutch drum using tool 50252 16-01.

Clutch drumModels 322/325Separate the shaft from the clutch cover.

Pull away the clutch cover complete withdrive axle and clutch drum.

The drum is bolted on the drive axle andcan be dismantled using tool 502 52 16-01.

The clutch drum should be replaced if thediameter exceeds Ø 64.0 mm.

The bearing supporting the clutch drumin the clutch cover is glued in position withLoctite. To replace the bearing, heat thecover to approx. 70°C using a hot air gunand the glue will release.

Dismantle the bearing using an appropri-ate punch and hammer.

Model 322CDismantle the clutch cover and removethe shaft’s mounting parts in the cover.

Remove the circlip.

Press off the clutch drum.

Replace the bearing and fit the remainingparts in the reverse order as set out fordismantling.

Now press out the clutch drum using asuitable punch and hammer.

The bearing is replaced in the same wayas described above.

Assemble in the reverse order as set outfor dismantling.

Model 322CDismantle the clutch cover from the shaft.

Remove the shaft’s mounting parts onthe clutch cover.

Dismantle the circlip holding the clutchdrum’s spindle by the bearing.

Assemble in the reverse order as set outfor dismantling.

Use Loctite intended for mounting bear-ings when the bearing is mounted in theclutch cover.

NOTE!

Dismantle the shaft’s mountingclamps and rubber spacer in theclutch cover so that these parts arenot damaged when the cover isheated.

100

4

531 00 48-62

531 00 48-62

Centrifugal clutch

Assemble the clutch in the reverse orderset out for dismantling and screw on theflywheel.

Assemble the clutch in the reverse orderset out for dismantling.

Watch the following:

● Turn the clutch so that the L-markingsface outwards.

● The flat washer should be positionedbetween the flywheel and the clutchshoes.

● Use Loctite on the screws and tightento a torque of 10 Nm.

Check the clutch shoes and replace them if:

● The lining is cracked or if bits are missing.

● The lining is worn down to 0.5 (new lining is approx. 2 mm thick).

● The lining is oily and feels soft.

● The bearing hole is worn.

Check the springs for wear to the ends.

Clean the clutch using compressed airand a brush. Do not use solvents as thiscan affect the linings.

Twist open the clutch.

Clean the clutch using compressed airand a brush. Do not use any form ofsolvent as this can affect the linings.

Twist open the clutch.

ClutchModel 122Dismantle all components so that theclutch is accessible.

Remove the screws and lift out the clutch.

ClutchModel 122Dismantle all components so that theclutch is accessible. Also refer to chapter,"Ignition system".

Remove the 2 screws that hold the clutchon the flywheel.

NOTE!

Use the tool no. 531 00 48-62 toavoid damage to the soft clutchlinings.

101

4Centrifugal clutch

Clutch drumModel 122Separate the engine and clutch housing.

Clutch drumModel 122Separate the engine and clutch housing(see page 25).

Loosen the screw and pull off the clutchhousing complete with drive line.

Remove the circlip and heat the clutchhousing.

Remove the circlip and heat the clutchhousing using a hot air gun to approx. 150– 200°C.

Pull the clutch drum complete with bear-ing and drive axle out of the clutch hous-ing.

Pull the clutch drum complete with bear-ing and drive shaft out of the clutch hous-ing.

Carefully knock the clutch housing'smounting flange with a plastic mallet.

Clamp the drive shaft's hexagonal sec-tion in a vice and tap off the clutch drumusing a hammer and brass punch.

Clamp the drive shaft's hexagonal sec-tion in a vice and tap off the clutch drumusing a hammer and brass punch so thatthe clutch drum is not damaged.

NOTE!

The clutch drum can be extremelytight.

102

4

504 91 06-05

Centrifugal clutch

ClutchModel 32 and MondoDisconnect the throttle cable and shortcircuit cables and dismantle the shaftfrom the clutch cover.

ClutchModel 32 and MondoDisconnect the throttle cable and shortcircuit cables (see page 54).

Loosen the screws that hold the shaft anddismantle it from the clutch cover.

Remove the screws and lift off the clutchcover.

Remove the screws that hold the clutchcover on the starter and then lift off theclutch cover.

Replace the spark plug with the pistonstop (504 91 06-05) and remove the nutsholding the clutch. (1/2" spanner.)

Dismantle the clutch.

Check the clutch drum with regard towear (inner diameter must not exceed 58mm) and crack formation by the hub onthe drum.

Fit a new clutch drum if necessary.

Assembly takes place in the reverse or-der set out for dismantling.

NOTE!

Do not forget the circlip betweenthe clutch drum and the bearing.

103

4

A

A

B

Centrifugal clutch

Strip the clutch. Strip the clutch using a screwdriver ifnecessary.

Check the clutch hub for wear. Check the clutch hub for wear to the guidearms (A) and play on the axle hole (B).

Check the clutch shoes for wear. Check the clutch shoes for wear. Theremust be at least 1 mm of material remain-ing at the most worn spot.

Also check the guide slot for wear.

First position the spring in one of theclutch shoes and then the clutch hub.

When assembling the clutch the springjoining point should be positioned in thecentre of one of the clutch shoes.

Then position the hub over the clutchshoe.

NOTE!

When replacing both shoes mustbe replaced.

104

4 Centrifugal clutch

Fit the remaining clutch shoe. Turn the clutch and position the remain-ing clutch shoe over the spring and pressonto the hub using your thumbs.

Assemble the clutch and the other partsin the reverse order.

Assemble the clutch and the other partsin the reverse order set out for disman-tling.

Clutch drumModel 32 and MondoReplace the clutch drum, bearing andclutch housing as a complete unit.

Clutch drumModel 32 and MondoIf the clutch drum and/or its bearing aredamaged they must be replaced as acomplete unit with the clutch housing.

Assembly takes place in the reverse or-der set out for dismantling.

ClutchModel 18HRemove the 4 screws and move the cut-ting equipment to one side.

ClutchModel 18HThe cutting equipment must be dismantledfrom the engine body to access the clutch.

Remove the 4 screws and move the cut-ting equipment to one side.

NOTE!

Do not forget the large flat washerbetween the clutch and thecrankcase.

The washer acts as a support forthe clutch shoes, and if missingthe shoes can be forced out of thehub when the engine is runcausing damage to the crankcase.

Turn the clutch so that the text onthe hub faces outwards.

105

4

504 91 06-05

Centrifugal clutch

Clutch drumModel 18HSee chapter "Attachments".

Clutch drumModel 18HSee chapter "Attachments".

Dismantle the clutch by prying out thesprings with a small screwdriver.

Inspect the clutch with regard to damageand wear.

Dismantle the clutch and inspect the partswith regard to damage or wear. Replacerequisite parts and assemble in the re-verse order as set out for dismantling.

Dismantle the clutch from the crankshaftusing an appropriate punch and hammer.

If the clutch is sitting extremely tight andthe compression pressure is not sufficientas a stop, the spark plug can be replacedby the piston stop no 504 91 06-05.

Dismantle the clutch using an appropri-ate punch and hammer.

Assemble the clutch in the reverse orderas set out for dismantling.

NOTE!

Both clutch shoes should bereplaced at the same time toprevent imbalance.

106

Mondo

122L

Mondo Max

225L/LD

232L

Mondo Mega

225R/RD

232R

322

325

235R

240R

245R

250R

245RX

250RX

252RX

265RX

240RBD

235P

250PS

225E

18H

225H60/75

225AI15, 225AI25

4

4,000 – –

3,900 Ø 58.0 Min. 0.5 mm of lining remaining

4,000 – –

3,700 Ø 64.5 Max 1 mm wear per shoe

3,800 Ø 64.5 Max 1 mm wear per shoe

4,000 – –

3,700 Ø 64.5 Max 1 mm wear per shoe

3,800 Ø 64.5 Max 1 mm wear per shoe

3,800 Ø 64.0 Max 1 mm wear per shoe

3,800 Ø 64.0 Max 1 mm wear per shoe

3,800 Ø 64.5 Max 1 mm wear per shoe

3,700 Ø 65.0 Max 1 mm wear per shoe

3,700 Ø 65.0 Max 1 mm wear per shoe

4,300 Ø 70.0 Max 1 mm wear per shoe

3,700 Ø 65.0 Max 1 mm wear per shoe

4,300 Ø 70.0 Max 1 mm wear per shoe

4,300 Ø 70.0 Max 1 mm wear per shoe

3,500 Ø 80.0 Max 1 mm wear per shoe

3,600 Ø 64.5 Max 1 mm wear per shoe

3,900 Ø 64.5 Max 1 mm wear per shoe

4,300 Ø 70.0 Max 1 mm wear per shoe

3,700 Ø 64.5 Max 1 mm wear per shoe

4,600 Ø 62.5 Max 1 mm wear per shoe

5,400 Ø 64.5 Max 1 mm wear per shoe

5,400 Ø 64.5 Max 1 mm wear per shoe

Technical data

Model Engage speed Wear limit Wear limitr/min clutch drum clutch shoe

Centrifugal clutch

107

Angle gear

5.

ContentsAll models _____________________________ 108

Dismantling, model 265 ____________________ 108

Assembling, model 265 ____________________ 110

Dismantling, assembling, models 250, 240/245 _ 112

Dismantling, assembling, models 225/232______ 114

Dismantling, assembling, models 322/325______ 116

Dismantling, assembling, models 122, 32, 235 __ 117

Technical data ____________________________ 118

108

5

502 51 68-01

Angle gear

Secondly, the angle gear contributes towards theoperator's working stance so that it is comfortableand at the same time efficient. In other words, thepower from the engine via the drive shaft shall beangled so that the cutting equipment works paral-lel with the ground.

The angle gear has two purposes:The first is to gear down the engine's high speed tobetter suit the lower speed a blade or trimmerrequires to work efficiently.

All modelsDismantle the cutting equipment (blade,trimmer, etc.) with its guard.

Now loosen the screws/screw that holdthe angle gear on the tube.

Remove the angle gear from the tube.

Use a screwdriver if necessary to split theclamping bracket.

DismantlingModel 265Dismantle the stop sleeve/seal holder.

DismantlingModel 265Dismantle the combined stop sleeve andseal holder for the input shaft using thetool 502 51 68-01.

NOTE!Press the tool firmly in the stopsleeve so that the slot is notdamaged when dismantling.

109

5

502 50 65-01

502 51 49-01

Angle gear

Lift out the output shaft. Now dismantle the output shaft and bear-ing, while the gear housing is still warm.

Use puller no. 502 50 65-01 if necessaryon older versions of the angle gear.

Heat the gear housing and knock it with awooden block so that the input shaft fallsout.

Clean all grease from the gear housingand heat the housing to approx. 150°C.

Knock the gear housing with a woodenblock so that the input shaft with bearingfalls out.

Dismantle the seal holder cover. Dismantle the seal holder cover usingpuller no. 502 51 49-01. Bearing puller no.504 90 90-01 can also be used.

Tip!Clamp the puller arms in a vice if the coveris really tight and the puller loses its grip.

Remove the screws. Remove the 3 screws that hold the sealholder cover on the gear housing.

110

5

504 90 90-01

505 38 17-09

Model 265

1.

2.3.

Model 265

From serial number > 64 90 191

A

A

Angle gear

Remove the bearings from the input andoutput shafts.

Remove the circlip on the input shaft andremove the bearing using puller no.504 90 90-01.

Dismantle the bearing on the output shaftin the same way.

Remove the bearing and sealing ringfrom the seal holder cover.

Heat the seal holder cover and removethe bearing and sealing ring at the sametime using punch no. 505 38 17-09.

AssemblingModel 265Fit the bearings on resp. shafts. It's easierif the bearing is heated to approx. 100°C.

Heat the gear housing to approx. 150°Cand insert the output shaft first and thenthe input shaft.

Make sure the bearing bottoms in itsseating.

The parts (A) are only supplied withspare part gears. This is so the gearscan be fitted on the old 165R where thedrive axle also had a spline on the clutchdrum.

The parts (A) prevent the drive axle fromsliding down through the pinion gear to-wards the gear on the blade axle. Mountedinside the pinion gear axle.

In those cases the drive axle is threadedby the clutch drum these parts are notrequired.

From serial number 64 90 191 the sealingring has been removed and replaced withthe three parts listed below.

1. Steel spacer2. Aluminium ring3. O-ring

The operating temperature falls consid-erably when the sealing ring is removedand is replaced by the new components.In addition, the steel spacer prevents theblade axle from shifting upwards, e.g.with impact from below.

NOTE!Do not forget the circlip that holdsthe bearing on the input shaft.

111

5

502 51 68-01

504 91 28-00

504 91 28-00

Angle gear

Change the seal//O-ring if necessary andassemble the seal holder cover on thegear housing using a suitable punch.

Fit a new bearing and new sealing ring inthe seal holder cover.

Heat the seal holder cover to approx.150°C and insert a new bearing in thebearing seating.

Fit a new sealing ring using punch no.504 91 28-00.

Turn the sealing ring so that the scraperedge faces the gear.

Screw in the stop sleeve. Screw in the stop sleeve using tool no.502 51 68-01. Make sure the lugs on thetool are pressed well into the slots in thestop sleeve when tightening so that theslots are not damaged.

Tightening torque: 45 Nm.

Change the sealing ring in the stop sleeveand change the O-ring if necessary.

Fit a new sealing ring in the stop sleeve.Position the seal so that the scraper edgefaces in towards the gear!

Use a suitable punch so that the sealingring is not damaged.

Use Loctite on the screws and tighten toa torque of 9 Nm.

NOTE!Turn the cover so the holes for thelocking pin are correctlypositioned.

112

503 97 64-01

5

Ø 21.5 mm

Angle gear

Fill the gear housing 3/4 full using specialgrease.

Remove the plug and fill the gear housing3/4 full with special grease no.502 51 27-01.

On later models of the angle gear (fromserial number 62 60 067) another type ofdrive disc has been fitted to preventgrass and dirt from penetrating into theangle gear and destroying the sealingring. The new drive disc has order no.502 25 41-02.

It can be fitted to angle gears that havecover with order no. 502 10 72-02 and502 10 72-03. The centre hole in the coveris Ø 22 mm.

Check the sealing ring in the tube (latermodels).

Replace if necessary.

Before the angle gear is fitted check thatthe sealing ring on the tube is undam-aged. When replacing pry the seal holderout using a screwdriver.

Fit a new sealing ring with the scraperedge facing the angle gear.

Dismantling, assemblingModels 250, 240/245Remove the cover, O-ring and washer.

Dismantling, assemblingModels 250, 240/245Remove the 3 screws holding the cover.

Lift off the cover, O-ring (240/245) andwasher positioned against the bearing.

! WARNING!Too much grease canmean it is forced passedthe sealing rings.The temperature in thegear can also be too high.

113

502 50 65-01

Model 250

Model 250

Serial number > 710 00 065 (250RX)

Serial number > 710 00 122 (250R)

A

5

502 52 17-01

B

Model 240, 245

Angle gear

Heat the gear housing and dismantle theinput and output shafts in the same wayas described for model 265.

Undo the ring nut. Undo the ring nut holding the input shaftin position using tool no. 502 52 17-01.

NOTE!The input shaft with drive gearmust be dismantled first. Usepuller no. 502 50 65-01 when theoutput shaft is dismantled.

NOTE!On new designs of the angle gearfor model 240/245 the sealingring (B) has been replaced withan O-ring, an aluminium ring anda steel spacer.

NOTE!The sealing ring on later modelshas been replaced by an O-ringand an aluminium sleeve (A).

Heat the gear housing to approx. 150°Cand first lift the output axle in position andthen the input axle. Make sure the bearingbottoms in its seating.

Replace damaged parts.

Assemble the angle gear in the reverseorder set out for dismantling.

Fit the bearings on respective axles. It iseasier if the bearing is heated to approx.100°C.

NOTE!Do not forget the circlip holdingthe bearing on the input axle.Make sure the bearing bottoms inits seating.

114

502 52 15-01

503 97 64-01

A

Model 240, 245

C

•

5

From date code 96391 on the gear housing

The operating temperature in the anglegear falls considerably when the sealingring is removed and replaced by the newcomponents (C). In addition, the steelspacer prevents the blade from shiftingupwards, e.g. with impact from below.

Fit the cover.

Check and possibly replace the sealingring and O-ring (A) at the ends of theshaft.

Check that the sealing ring and O-ring(A), at the end of the shaft, are undam-aged before the gear is fitted.

Do not forget to fill the gear housing 3/4full with special grease 503 97 64-01.

Dismantling, assemblingModels 225/232Remove the circlip and washer on theoutput shaft.

Dismantling, assemblingModels 225/232Dismantle the angle gear from the shaft.

Remove the circlip and washer on theoutput shaft.

!

NOTE!Use the centring sleeve no.502 52 15-01 to centre the coveron the gear housing.Use Loctite on the screws.

WARNING!Too much grease can mean itis forced passed the sealingrings. The temperature in thegear can also be too high.

Angle gear

115

503 97 64-01

5

Model 225/232

Angle gear

Fill the gear housing with grease. Do not forget to fill the gear housing 3/4full using special grease. 503 97 64-01.

Replace worn or damaged parts and as-semble the angle gear in the reverseorder set out for dismantling.

Heat the gear housing to about 150–200°C and start by fitting the output shaft.

Heat the entire gear housing using a hotair gun to about 150–200°C.

First dismantle the input shaft by knock-ing the gear housing with a wooden blockuntil the shaft and bearing fall out.

Then dismantle the output shaft in thesame way.

Heat the gear housing and first dismantlethe input shaft and then the output shaft.

Remove the plastic washer and circlip onthe input shaft.

Remove the plastic seal on the input shaftusing a suitable screw (M8).

Now remove the large locking ring hold-ing the bearing in position in the gearhousing.

!WARNING!Too much grease canmean it is forced passedthe sealing rings. Thetemperature in the gearcan also be too high.

116

5

A

B

C

D

Angle gear

Dismantling, assemblingModels 322/325Remove the angle gear from the shaft.

Remove the circlips holding the bearingson the input respective output axles.

Dismantling, assemblingModels 322/3251. Remove the cutting equipment and

guard.

2. Loosen the screw holding the anglegear on the shaft and remove theangle gear.

3. Remove the circlips holding the bear-ings on the output axle (illustrated)and on the input axle using the circlippliers.

Heat the entire angle gear to approx.110°C and first dismantle the input axleand then the output axle.

Heat the entire angle gear using a hot airgun to approx. 110°C.

Knock the gear against a wooden blockso that the input axle and the bearing fallout.

Now lift out the output axle.

Wear protective gloves.

AssemblyClean all component parts and replace ifdamaged or worn.

Fit the bearings on respective axles. Thisis easier if the bearings are heated toapprox. 110°C using a hot air gun.

NOTE!Do not forget to fill the gearhousing to approx. 3/4 with gearhousing grease 503 97 64-01 oncethe plug (D) has been removed.

Heat the gearbox to approx. 110°C andfirst place the output axle in position andthen the input axle.

Make sure the bearing bottoms in itsseating.

Fit the circlips (B) and (C). Make sure theylie correctly in their grooves.

Assemble remaining parts in the reverseorder as set out for dismantling.

NOTE!Do not forget the circlip (A)holding the bearing on the inputaxle.

117

Models 122, 32, 235

503 97 64-01

5Angle gear

Replace damaged parts.

Assemble the angle gear in the reverseorder set out for dismantling.

Fill the gear housing 3/4 full using specialgrease. 502 97 64-01.

First dismantle the input shaft by knock-ing the gear housing with a wooden blockuntil the shaft and bearing fall out.

Then dismantle the output shaft in thesame way.

First dismantle the input shaft and thenthe output shaft.

Dismantling, assemblingModels 122, 32, 235Remove the circlips from the input andoutput shafts.

Heat the gear housing.

Dismantling, assemblingModels 122, 32, 235Remove the circlips holding the bearingson the input and output shafts.

Heat the entire gear housing using a hotair gun to about 150–200°C.

NOTE!Unscrew the stop screw enoughso that it does not prevent theshaft from sliding out.

118

5

Mondo

122L

Mondo Max

225L/LD

232L

Mondo Mega

225R/RD

232R

322

325

235R

240R

245R

250R

245RX

250RX

252RX

265RX

240RBD

235P

250PS

225E

18H

225H60/75

140B/141B

132HBV

225BV/225HBV

1:1 3/8"x24(R) – – 30° 9,000

1:1.33 M10x1.25 – – 35° 8,100

1:1.23 3/8"x24(L) – – 30° 7,300

1:1.40 M10x1.25 – – 35° 8,500

1:1.40 M10x1.25 _ _ 35° 8,500

1:1.33 3/8"x24(L) 20.0 200 30° 7,300

1:1.40 M10x1.25 20.0 200–255 35° 8,500

1:1.40 M10x1.25 20.0 200–275 35° 8,500

1:1.46 M10x1.25 25.4 200–255 30° 8,560

1:1.46 M10x1.25 25.4 200–255 30° 8,560

1:1.53 M12x1.75 20.0 200–300 35° 7,800

1:1.36 M12x1.75 20.0 200–300 30° 9,190

1:1.36 M12x1.75 20.0 200–300 30° 9,190

1:1.36 M12x1.75 20.0 200–300 30° 9,190

1:1.36 M12x1.75 20.0 200–300 30° 9,190

1:1.36 M12x1.75 20.0 200–300 30° 9,930

1:1.36 M12x1.75 20.0 200–300 30° 10,300

1:1.26 M12x1.75 20.0 200–300 25° 9,120

1:1.40 M10x1.25 20.0 200–300 35° 7,800

– – – – – –

– – – – – –

1:1.40 M10x1.25 25.4 – 35° 8,500

1:5.7 – – – – –

1:7.25 – – – – –

– – – – – –

– – – – – –

– – – – – –

Angle gearTechnical data

Model Gear ratio Axle thread Blade hole Blade diameter Angle Max. axle speeddiameter mm degrees rpm

mm

119

6.

ContentsDismantlingGeneral ________________________________________ 120

Dismantling, cleaning, inspection, assemblingModels 250, 265 _________________________________ 120

Models 240/245 _________________________________ 122

Models 225/232/235/240RBD ______________________ 124

Models 322, 325 _________________________________ 127

Models 122 _____________________________________ 129

Models 32 ______________________________________ 131

Models Mondo __________________________________ 132

Models 18H _____________________________________ 136

Models 140B/141B _______________________________ 137

Analyse and measures __________________________ 139

Service tips ______________________________________ 144

Wear limits _______________________________________ 144

Technical data ___________________________________ 145

Cylinder and piston

120

6

504 90 00-02

Cylinder and piston

Cleanliness is extremely important when servic-ing these components. We therefore recommendthat the cylinder and the area around it is cleanedthoroughly before it is dismantled from the crank-case.With regard to Husqvarna E-TECH see chapter“Crankshaft and crankcase”.

The cylinder and piston are two components thatare exposed to the most strain in the engine. Forexample, they should withstand high speed, largechanges in heat and high pressure. In addition,they should withstand wear. Despite the hardworking conditions serious cylinder and pistonfailures are quite unususal. Some of the reasonsbehind this are the new coating materials in thecylinder bore, new lubricants and improvedmanufacturing techniques.

DismantlingGeneralThe dismantling routines are basically the same for all models. However, in those caseswhere the procedure deviates for a particular model, this is specially described.

Dismantle the following:

Cylinder cover, air filter, carburettor, muffler, starter and on some models the ignitionmodule and flywheel.

See respective sections in the Workshop Manual for detailed instructions.

Models 250, 265Loosen the 4 screws holding the cylinderon the crankcase.

Models 250, 265Dismantle all the components around thecylinder and loosen the 4 screws holdingthe cylinder on the crankcase. Use theallen key 504 90 00-02.

Lift off the cylinder. Lift up the cylinder a little and place a clothin the crankcase opening to prevent dirtfrom falling into the crankcase.

Lift off the cylinder from the piston.

121

6

505 38 17-05

Cylinder and piston

Cleaning, inspection models 250, 265After dismantling clean the different parts:

1. Scrape off the carbon deposit from the crown of the piston.

2. Scrape off the carbon deposit in the cylinder's combustion chamber.

3. Scrape off the carbon deposit in the cylinder's exhaust port.

Dismantle the piston. Press out the gudgeon pin from the pistonusing punch 505 38 17-05.

If the gudgeon pin is difficult to removethe piston can be carefully heated.

Remove the circlips on the gudgeon pin. Use flat nose pliers to remove the circlipson the gudgeon pin.

Keep your thumb over the circlip to stop itfrom flying away.

4. Wash all parts.

5. Inspect all the parts for wear or damage.

6. Check the manifold with regard to crack formation, whether leakage has occurred,etc. Refer to the section “Analysis and actions”.

Check the piston and cylinder for signs of seizing damage and wear.

Refer to the section “Analysis and actions”.

Check the piston rings for signs of wear or breakage.

Refer to the section “Analysis and actions”.

Check the gudgeon pin.

– If it is blued it should be replaced.

– If it runs too easily in the piston then the piston and gudgeon pin should be replaced.

Check the needle bearing. If it is miscoloured it should be replaced.

Always replace the circlips on the gudgeon pin.

NOTE!Scrape carefully with a tool that is not too sharp so that the soft aluminiumparts are not damaged.

122

6

502 50 70-01

Cylinder and piston

AssemblingModels 250, 265Lubricate the gudgeon pin's needle bear-ing with a few drops of engine oil and fitthe piston.

AssemblingModels 250, 265Lubricate the gudgeon pin's needle bear-ing with a few drops of engine oil.Point the arrow on top of the piston to-wards the exhaust port.Press in the gudgeon pin and fit the circlips.

Check that the piston and cylinder havethe right classification to fit together.

There is a classification letter punchedon top of the piston so that it can be pairedwith the right cylinder:

A piston punched with the same letter ora previous letter in the alphabet will fit thecylinder.

A piston stamped AB fits a cylinderstamped B.

Fit the manifold on the cylinder.

Use a new gasket and fit the cylinder.

Place a new cylinder bottom gasket onthe crankcase.

Fit the manifold on the cylinder. Makesure the gaskets are facing the right wayso that the pulse channels to the carbu-rettor are not blocked.

Lubricate the piston with a few drops ofengine oil and fit the cylinder using as-sembly kit 502 50 70-01.

Tighten the cylinder base bolts.

DismantlingModels 240/245Dismantle all parts surrounding the cylin-der.

DismantlingModels 240/245Dismantle the following components:

Cylinder cover, spark plug, starter, airfilter, carburettor, heat guard, inlet mani-fold, muffler, heat shield, ignition module,flywheel.

See respective sections in the Manual.

NOTE!Place a cloth in the crankcaseopening to prevent the circlipsfrom falling into the crankcase ifthey should fly off.Check that the circlips are sittingin the grooves correctly byturning the circlip using a pair ofpliers.

123

6Cylinder and piston

Remove the cylinder bolts.

Lift off the cylinder and dismantle thepiston.

Remove the four bolts at the bottom ofthe crankcase.

Lift off the cylinder.

Dismantle the circlips on the gudgeonpin. (See models 250, 265).

Remove the piston. (See models 250,265).

Cleaning, inspectionModels 240/245Clean and inspect the cylinder and pistonand associated parts.

Cleaning, inspectionModels 240/245Clean and inspect the cylinder, piston,piston ring, gudgeon pin and needle bear-ing as described for models 250, 265.

Also see section “Analysis and actions”.

Check the inlet manifold and the heatguard.

Check the inlet manifold and the heatguard for crack formation in the materialand on the threads.

Replace damaged parts if necessary.

AssemblingModels 240/245Fit the piston.

AssemblingModels 240/245Lubricate the gudgeon pin's needle bear-ing with a few drops of engine oil.Point the arrow on top of the piston to-wards the exhaust port.Press in the gudgeon pin and fit thecirclips.

NOTE!Make sure when cleaning thecylinder that the plastic sleeve bythe pulse channel is not lost.

NOTE!Place a cloth over the big-endbearing.Check that the circlips are sittingin the grooves correctly by turningthe circlip using a pair of pliers.

124

6

503 26 70-01

Cylinder and piston

Cleaning the contact face and the bear-ing seat and apply a string of sealant.

Clean the contact face on the bottom ofthe cylinder and bearing seat so thatthere are no signs of grease.

Apply a thin string (1–1.5 mm) of sealantno. 503 26 70-01 on the contact face.

Fit the cylinder. Lubricate the piston, piston ring and bear-ing with engine oil.

Guide the cylinder over the piston andcarefully press it down towards the crank-case.

Tip!Move the cylinder gently from side-to-sideat the same time as you press it down.

Tighten the cylinder bolts. Tighten the cylinder bolts crosswise to atorque of 11 Nm.

Fit the heat guard on the cylinder.

Check that the inlet manifold and pulsemanifold are positioned correctly and donot leak.

DismantlingModels 225/232/235/240RBDDismantle all the parts surrounding thecylinder.

DismantlingModels 225/232/235/240RBDDismantle the following parts:

Cylinder cover, spark plug, starter, airfilter, carburettor, ignition module, muf-fler, heat guard, flywheel.

See respective sections in the Manual.

NOTE!Only this type of sealant must beused.

NOTE!Do not turn the cylinder. Thepiston rings can break.

NOTE!The cylinder bolts should beretightened.Run the engine warm for 2–3 minand let it cool.Retighten the cylinder boltscrosswise to a tightening torque of11 Nm.

125

6Cylinder and piston

Check the inlet manifold. Check the inlet manifold for crack forma-tion and damage to the contact faces tothe carburettor and cylinder.

Cleaning, inspectionModels 225/232/235/240RBDClean and inspect the cylinder and pistonand associated parts.

Cleaning, inspectionModels 225/232/235/240RBDClean and inspect the cylinder, piston,piston ring, gudgeon pin and needle bear-ing as described for models 250, 265.

Also see section “Analysis and actions”.

Carefully remove old gasket residue fromthe contact face at bottom of the cylinder!

Place a cloth over the crankshaft anddismantle the piston.

Place a cloth over the crankshaft.

Dismantle the circlips on the gudgeon pin.(See models 250, 265).

Dismantle the piston. (See models 250,265).

Dismantle the cylinder. Remove the four bolts at the bottom of thecylinder.

Pull the cylinder forwards so the inletmanifold releases from the connection onthe cylinder.

Lift off the cylinder and at the same timepress down the crankshaft in its positioninside the crankcase so that it does notfollow the cylinder.

NOTE!Pay attention to the small plasticring on the carburettor connectionso that it is not lost duringcleaning.

126

6

503 26 70-01

Cylinder and piston

AssemblingModels 225/232/235/240RBDFit the piston.

AssemblingModels 225/232/235/240RBDLubricate the gudgeon pin's needle bear-ing with a few drops of engine oil.Point the arrow on top of the piston to-wards the exhaust port.Press in the gudgeon pin and fit the circlips.

Fit the inlet manifold. Lubricate the outside of the inlet manifoldwith a few drops of engine oil and fit it tothe insulation wall on the crankcase.

Check that the contact face at the bottomof the cylinder is clean and free of grease.Apply a narrow string of sealant.

Check that the contact faces on the crank-case and at the bottom of the cylinder areclean and free of grease and sealant.

Apply a thin string (1–1.5 mm) of sealantno. 503 26 70-01 on the contact face.

Lubricate the inlet manifold's connectionon the cylinder with a few drops of engineoil.

Lubricate the piston, piston ring and bear-ing with engine oil.

Lubricate the inlet manifold's connectionon the cylinder with a few drops of engineoil.

Lubricate the piston, piston ring and bear-ing with engine oil.

NOTE!Only this type of sealant must beused.

NOTE!Place a cloth over the big-endbearing.Check that the circlips are sittingin the grooves correctly by turningthe circlip using a pair of pliers.

NOTE!

Do not forget to position the smallplastic ring in the inlet manifold.

127

6

1

2

3

4

504 90 00-02

Cylinder and piston

Remove the bolts holding the cylinder. Remove the 4 bolts holding the cylinderagainst the crankcase.

Use tool no. 504 90 00-02.

DismantlingModels 322, 325Dismantle the following parts:

Cylinder cover, muffler grille, muffler withheat guard plate, starter and spark plug.Move the fuel tank.

Now remove the 2 screws holding thedistance piece against the crankcase.

Remove the distance piece with the at-tached carburettor.

DismantlingModels 322, 325Dismantle all parts around the cylinderincl. the distance piece with attached car-burettor.

Tighten the cylinder bolts crosswise to atightening torque of 11 Nm.

Retighten the bolts.

Tighten the cylinder bolts crosswise to atightening torque of 11 Nm.

Fit the cylinder.

Check the connection of the inlet mani-fold on the cylinder.

Guide the cylinder over the piston andcarefully press it down towards the crank-case.

Tip!Move the cylinder gently from side-to-sideat the same time as you press it down.

NOTE!Do not turn the cylinder. Thepiston ring can break.Make sure the inlet manifold isconnected correctly on thecylinder.

NOTE!The cylinder bolts should beretightened.Run the engine warm for 2–3 minand let it cool.Retighten the cylinder boltscrosswise to a tightening torqueof 11 Nm.

128

6

505 38 17-05

503 26 70-01

Cylinder and piston

Lift off the cylinder and remove the pistonfrom the connecting rod.

Pull the cylinder straight up without turn-ing it. There is a risk that the piston ringmay break.

A sealant has been used instead of agasket on the base of the cylinder.

Dismantle the piston from the connectingrod.

Cleaning, inspectionModels 322, 325Clean and inspect the piston and cylin-der. Check the rubber induction manifoldwith regard to crack formation and otherdamage.

Cleaning, inspectionModels 322, 325Before the piston and cylinder are as-sembled the parts must be cleaned andinspected in the same way as describedfor models 250, 265. Also see section“Analysis and measures”.

Check that the rubber induction manifoldbetween the cylinder and distance pieceis not cracked nor has other damage thatcan cause leakage.

AssemblingModels 322, 325Clean the sealant from the crankcase andassemble the piston on the connectingrod.

AssemblingModels 322, 325Clean any sealant and grease from thecrankcase.

Fit the piston on the connecting rod sothat the arrow on the piston points to-wards the exhaust port.

Clean the contact surface at the base ofthe cylinder and apply a narrow bead ofsealant no. 503 26 70-01 on the contactsurface.

Clean any sealant and grease from thecontact surface on the base of the cylinder.

Apply a narrow bead (1–1.5 mm) of seal-ant no. 503 26 70-01 on the contact sur-face.

NOTE!Also apply sealant to the bearingseatings in the crankcase andcylinder if the old bearings are tobe refitted.No sealant is required if newbearings are fitted.

129

6

505 38 17-05

Cylinder and piston

Dismantle the piston. Use a pair of pliers to remove the gudgeonpin's circlip as described for models 250,265.

Press out the gudgeon pin using the punchno. 505 38 17-05.

If the gudgeon pin is difficult to remove thepiston can be carefully heated.

Lift off the cylinder. Lift up the cylinder a little and place a clothin the crankcase opening to prevent dirtfrom falling into the crankcase.

Lift off the cylinder from the piston.

DismantlingModel 122Dismantle all the parts surrounding thecylinder. Remove the two cylinder bolts.

DismantlingModel 122Dismantle the spark plug, cylinder cover,muffler, air filter, carburettor, fan cover,ignition module and carburettor manifold.

Remove the two bolts holding the cylin-der on the crankcase.

Carefully slide the cylinder over the pis-ton and tighten the 4 bolts crosswise.

Lubricate the piston using a few drops ofoil and carefully slide the cylinder over thepiston.

Tighten the 4 bolts crosswise.

Assemble the remaining parts in the re-verse order as set out for dismantling.

NOTE!Do not turn the cylinder, as thepiston ring can easily be broken.

130

6

502 50 70-01

505 38 17-05

531 00 48-65

Cylinder and piston

Cleaning, inspectionModel 122Clean and inspect the cylinder and pistonand associated parts.

Cleaning, inspectionModel 122Clean and inspect the cylinder, piston,piston ring, gudgeon pin and needle bear-ing as described for models 250, 265.

Also see section “Analysis and actions”.

AssemblingModel 122Fit the piston on the connecting rod.

AssemblingModel 122Lubricate the gudgeon pin's needle bear-ing with a few drops of engine oil.Point the arrow on top of the piston to-wards the exhaust port.Use the punch no. 505 38 17-05 to pushin the gudgeon pin.Press in the gudgeon pin and fit the circlips.

Use a new bottom gasket on the cylinderand fit the cylinder.

Fix a new bottom gasket using a littlegrease on to the cylinder and lubricatethe piston with a few drops of oil.

Place the support plate from the assem-bly kit no. 502 50 70-01 under the piston.

Press together the piston rings using tool531 00 48-65.

Carefully slide the cylinder down over thepiston. Check that the cylinder is posi-tioned correctly.

Fit the manifold on the cylinder and thecarburettor and the other parts in thereverse order set out for dismantling.

Place the combined gasket and heat guardbetween the cylinder and manifold. Donot forget to fit the throttle cable'stensioning unit on the upper, left-handscrew.

NOTE!Place a cloth over the big-endbearing. Check that the circlipsare sitting in the grooves correctlyby turning the circlip using a pairof pliers.

Tighten the bolts holding the cylinder.

NOTE!Do not turn the cylinder. Thepiston ring can break.

Fit the carburettor and the other compo-nents in the reverse order set out fordismantling.

NOTE!The spring washer and flat washershall sit between the sheet angleand the manifold.

131

6

502 50 57-01

Cylinder and piston

Cleaning, inspectionModel 32Clean and inspect the cylinder and pistonand associated parts.

Cleaning, inspectionModel 32Clean and inspect the cylinder, piston,piston ring, gudgeon pin and needle bear-ing as described for models 250, 265.

Also see section “Analysis and actions”.

Dismantle the piston. Dismantle the piston as described formodels 250, 265.

Remove both the cables from the ignitionmodule and dismantle the cylinder.

Remove both the cables from the ignitionmodule and undo the cylinder bolts.

Now lift the cylinder straight up.

Place a cloth in the crankcase opening toprevent dirt from falling into the crank-case.

DismantlingModel 32Dismantle the cylinder cover, spark plugand muffler.

DismantlingModel 32Dismantle the cylinder cover and sparkplug.

Remove the muffler.

Use a narrow blade screwdriver and pryout the springs.

!

NOTE!The gudgeon pin's bearing ispressed into the connecting rod.These parts should be replaced atthe same time if any of them aredamaged.

NOTE!Exercise care when the gudgeonpin is pressed out. There is a riskthat the pin's needle bearing canfall out and be lost.

WARNING!The springs are heavilytensioned and can fly outwhen loosened. Wearprotective glasses andprotect your hands.

132

6

502 50 70-01

505 38 17-05

504 90 00-02

Cylinder and piston

AssemblingModel 32Lubricate the gudgeon pin's needle bear-ing with a little grease.

AssemblingModel 32Lubricate the gudgeon pin's needle bear-ing with a little grease to keep the needlesin place.

Align the piston and gudgeon pin usingpunch no. 505 38 17-05. Carefully pressin the gudgeon pin.

Fit the circlips and check that they sitcorrectly in the groove by turning with apair of pliers.

Use a new bottom gasket on the cylinderand fit the cylinder.

Place a new bottom gasket on the crank-case.

Lubricate the piston and piston ring witha few drops of oil.

Fit the cylinder using assembly kit no.502 50 70-01.

Use Loctite on the bolts and tighten.

Fit the remaining parts in the reverseorder set out for dismantling.

DismantlingModel MondoMake a hole in the decal. Loosen thescrew and remove the cover.

DismantlingModel MondoDismantle the engine from the shaft unitand then remove the following parts:

Clutch, starter cover, spark plug, air filter,carburettor.

Make a hole in the decal and loosen thescrew that holds the cover.

Dismantle the cylinder cover and fueltank.

Remove the four bolts that hold the cylin-der cover.

Pry off the cover using a screwdriverplaced in between the fuel tank and cover.

Lift off the fuel tank.

133

6

502 50 57-01

A

B

C

B

505 38 17-05

Cylinder and piston

Dismantle the piston from the connectingrod.

Remove the two circlips on the gudgeonpin and press the pin out of the pistonusing the punch no. 505 38 17-05.

Dismantle the cylinder and connectingrod and the piston.

Remove the two bolts holding the cylinderusing an allen key with a 3/16" key handle(502 50 57-01).

Lift off the cylinder.

Now lift off the piston and connecting rodin one piece from the crankshaft.

Dismantle the muffler. Dismantle the muffler.

Use, a screwdriver, for example, as alever to stretch out one of the springs asillustrated.

Lift off the muffler.

Dismantle the short circuit cable andmanifold.

Dismantle the short circuit cable from theignition module (A).

Remove the bolts (B) holding the mani-fold (C).

Lift off the manifold.

134

6 Cylinder and piston

Cleaning, inspectionModel MondoClean and inspect the different cylinderand piston parts.

Cleaning, inspectionModel MondoClean and inspect the cylinder, piston,piston ring, gudgeon pin and needle bear-ing as described for models 250, 265.

Also see section “Analysis and actions”.

Scrape off any gasket residue from thecylinder and crankcase as well as fromthe manifold face on the carburettor side.

Replace the connecting rod complete withbearings if any of the parts have faults.

The needle bearings at both ends of theconnecting rod are pressed into place. Ifthey are heavily blued or show signs ofbreakage or wear the connecting rodcomplete with bearings should be re-placed.

AssemblingModel MondoFit the piston on the connecting rod.

AssemblingModel MondoLubricate the connecting rod's bearingswith a few drops of engine oil.Fit the piston on the connecting rod (endwith the smallest bearing).Fit one of the circlips for the gudgeon pinin the piston.Align the piston on the connecting boltand press in the gudgeon pin.Fit the other circlip.

Slide the piston a little way into the cylin-der.

Lubricate the piston and piston ring witha few drops of engine oil.

Slide the piston in so the ring just passesthe chamfer.

NOTE!Check that the circlips are sittingin the grooves correctly byturning the circlip using a pair ofpliers.

NOTE!The guide pin for the piston ringshould face the inlet port in thecylinder.

135

6Cylinder and piston

Fit the manifold on the cylinder.

Connect the short circuit cable.

Fit the manifold on the cylinder. Use anew gasket.

Use Loctite on the bolts.

Connect the short circuit cable on theignition module.

Fit the muffler. Fit the muffler.

First hook on the spring closest to theignition module.

Move the muffler down towards the cylin-der so the guides pins enter the corre-sponding cut-outs in the muffler.

Finally hook on the last spring using ascrewdriver in the same way as describedunder dismantling.

Place the connecting rod over the crankpin and slide down the cylinder.

Tighten the cylinder.

Place the connecting rod over the crankpin and slide down the cylinder over thepiston towards the crankcase contact face.

Tighten the cylinder with the two bolts.

Use Loctite on the bolts.

Use a new bottom gasket and make sureit is turned the right way.

Place a new gasket on the crankcase'scontact face.

Attach with a little grease if necessary.

Check that the cut-out in the gasket cor-responds with the cut-out in the crank-case.

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6

503 26 70-01

Cylinder and piston

Dismantle one of the springs holding themuffler.

Pry off one of the springs holding themuffler by using a small screwdriver.

Move the muffler away, but let it remainsuspended by the rear spring.

Dismantle the carburettor’s distance piecefrom the cylinder.

Remove both screws holding the carbu-rettor’s distance piece on the cylinder.

Carefully pry off the distance piece usinga screwdriver.

DismantlingModel 18HDismantle the spark plug, cylinder coverand carburettor.

DismantlingModel 18HDismantle the spark plug and cylindercover.

Remove the air filter cover and air filter.

Loosen the two screws holding the airfilter holder and carburettor.

Now lift off the carburettor.

Fit the combined crankcase half/cylindercover.

Apply a narrow string (1–1.5 mm) of seal-ant no. 503 26 70-01 of crankcase.

Position a new gasket.

Also apply a narrow string of sealant onthe contact face on the combined crank-case half/cylinder cover and put it in po-sition.

Tighten the four bolts.

Assemble the remaining parts in the re-verse order set out for dismantling.

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6

502 50 57-01

502 50 22-01

502 50 23-01

Cylinder and piston

Dismantle the cylinder and connectingrod and piston.

Remove the two screws holding the cy-linder using an allen key (3/16" key grip)no 502 50 57-01.

Lift off the cylinder with the muffler.

Remove the cover on the crankcase andlift off the piston and connecting rod.

Cleaning, inspectionand assemblyModel 18HPerformed in the same way as describedfor model Mondo.

Cleaning, inspectionand assemblyModel 18HPerformed in the same way as describedfor model Mondo.

DismantlingModel 140B/141BDismantle the cylinder cover.

DismantlingModel 140B/141BRemove the spark plug.

Unscrew the 3 bolts and lift off the cover.

Remove the cooling air plate and disman-tle the muffler.

Lift off the cooling air plate above thecylinder.

Dismantle the muffler by removing the 2screws.

NOTE!Hook the muffler in the rearspring before the cylinder isfitted. This facilitates assembly.

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6

504 90 00-03

Cylinder and piston

Dismantle the carburettor and throttlecable holder from the distance piece.

Dismantle the air filter, throttle cable holderand carburettor according to the instruc-tions in the chapter “Fuel system”.

Loosen the screws and lift off the cylinder. Loosen the 4 bolts holding the cylinderagainst the crankcase.

Lift off the cylinder straight upwards sothat the piston rings are not broken.

Dismantle the piston in the same way asdescribed for models 250, 265.

Cleaning and inspectionModel 140B/141BClean and inspect the different cylinderand piston parts.

Cleaning and inspectionModel 140B/141BClean and inspect the cylinder, piston,piston rings and gudgeon pin in the sameway as described for models 250, 265.

Also see section “Analysis and meas-ures”.

Scrape off any gasket residue from thebase of the cylinder and crankcase aswell as the contact surfaces for the dis-tance piece on the carburettor side.

NOTE!If the piston is to be dismantled fromthe connecting rod, the engine mustfirst be dismantled from the fan so thatone of gudgeon pin’s circlips can beremoved.

See chapter “Ignition system”.

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6

504 90 00-03 502 50 70-01

Analysis andactionsThe two pictures to the left show what anew piston looks like, one on the inlet sidethe other on the exhaust side. Note thatthe machining marks from manufacturingare clearly visible.

Use these pictures as a reference whendetermining damage and wear.

Experience tells us that piston or cylinderfailures due to manufacturing errors areextremely rare.

The reason is usually due to other factors,which is evident from the following.

Note the reasons for the breakdown, re-pair the damage and take the actions toprevent the same thing happening again.

New piston, exhaust side.New piston, inlet side.

Small and medium size scores primarily infront of the exhaust port.

Cylinder and piston

AssemblingModels 140B/141BAssembly takes place in the same way asdescribed for model 122.

AssemblingModels 140B/141BAssembly takes place in the same way asdescribed for model 122.

Insufficient lubricationThe piston has small to medium size score marks usually in front of the exhaust port.In extreme case heat development can be so great that material from the piston smearsalong the piston skirt and even in the cylinder bore.

Generally the piston ring is undamaged and moves freely in the ring groove.

There can also be scores on the inlet side of the piston.

Reason:● Incorrect carburettor setting. Recom-

mended max. speed exceeded.

● Incorrect oil mixture in the fuel.

● Fuel has too low octane value.

Action:Check and change the carburettor set-ting.

Change the fuel.

Change to a higher octane petrol.

Use assembly kit no. 502 50 70-01 andtool 502 50 70-01 when the cylinder isfitted on the crankcase.

Assemble remaining parts in the reverseorder as set out for dismantling.

NOTE!If the piston has been dismantledfrom the connecting rod it isassembled so that the locking pinscome towards the exhaust port.

140

6 Cylinder and piston

Medium to deep scores along the entirepiston skirt on the exhaust side.

Heavy scoring along the entire piston skirton the exhaust side.

Medium to deep scores on the exhaust side.The piston ring is stuck in the groove.Black miscolouration under the piston ringdue to blow-by.

The piston ring starts to stick or is completely stuck in its groove and has therefore notbeen able to seal against the cylinder wall, which has resulted in further, intensivetemperature increases on the piston.

Seizure scores along the entire piston skirt on the inlet and exhaust sides.

Piston scoring caused by heavy carbon depositsToo heavy carbon depositing can cause damage similar to that caused by insufficientlubrication. However, the piston skirt has a darker colour caused by the hot combustiongases that are blown past the piston.

This type of piston damage starts at the exhaust port where carbon deposits canbecome loose and trapped between the piston and cylinder wall.

For the best results we recommend Husqvarna two-stroke oil, which is speciallydeveloped for air-cooled two-stroke engines.

Mixing ratio: 1:50 (2%).

If Husqvarna two-stroke oil is not available another good quality two-stroke oil can beused.

Mixing ratio: 1:33 (3%) or 1:25 (4%).

Cause:● Incorrect oil mixture in the fuel.

● Fuel has too low octane value.

● Air leaks.

Cracked fuel pipe.

Leaking inlet gaskets.

Cracked manifold or inlet manifold.

● Air leakage in engine body.

Leaking crankshaft seals.

Leaking cylinder and crankcasegaskets.

● Bad maintenance

Dirty cooling fins on the cylinder.

Blocked air intake on the starter.

Blocked spark arrest screen on themuffler.

Action:Change the fuel.

Change to a higher octane petrol.

Replace damaged parts.

Replace leaking gaskets and shaft seals.

Clean the cooling fins and air intake.

Clean or replace the spark arrest screen.

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6Cylinder and piston

Inlet side. The piston ring is stuck in itsgroove. Black discolouration under the pis-ton ring due to blow-by.

Exhaust side damaged by a broken pistonring. The piston ring parts damage the topsection and cause score marks.

Typical for this type of piston damage is brown or black discolouration of the piston skirt.

Cause:● Wrong type of two-stroke oil or petrol.

● Incorrect oil mixture in the fuel.

● Incorrect carburettor setting.

Action:Change the fuel.

Change to a fuel with the right oil mixture.

Correct the carburettor setting.

Piston damage caused by a too high engine speed.Typical damage associated with a too high engine speed is broken piston ring, brokencirclips on the gudgeon pin, faulty bearings or that the guide pin for the piston ring hasbecome loose.

Piston ring breakageA too “lean” carburettor setting results in a too high speed and a high pistontemperature. If the piston temperature rises above the normal working temperature thepiston ring can seize in its groove, consequently it will not sit deep enough in its groove.The edges of the piston ring can then hit the top edge of the exhaust port and besmashed and also cause piston damage.

A too high engine speed can also cause rapid wear to the piston ring and play in thepiston ring groove primarily in front of the exhaust port. The ring is weakened by thewear and can be caught in the port causing serious piston damage.

142

6 Cylinder and piston

The guide pin for the piston ring has beenpushed up through the top of piston.

Piston ring guide pinvibrated looseA too high engine speed can cause theends of the piston ring to hammer againstthe guide pin when the piston ring moves inits groove. The intensive hammering candrive out the pin through the top of thepiston causing serious damage also to thecylinder.

Irregular grooves on the piston's inlet sidecaused by a broken roller retainer.

Deep, irregular grooves caused by a loosecirclip. Shown here on the piston's inlet side.

Small score marks and a matt, grey surfaceon the piston's inlet side caused by fine dustparticles.

Bearing failureA failure on the crankshaft bearing or on theconnecting rod bearing is usually caused bya too high engine speed, resulting in thebearing being overloaded or over heating.This in turn can cause the bearing rollers orball to glide instead of rotate, which canmean the roller or ball retainer breaks.

The broken debris can be trapped betweenthe piston and cylinder wall, damaging thepiston skirt.

Debris can also pass up through the cylin-der's transfer channels and cause damageto the top and sides of the piston as well asthe cylinder's combustion chamber.

Damage caused bygudgeon pin circlipsA too high engine speed can cause thegudgeon pin circlips to vibrate. The circlipsare drawn out of their groove due to thevibrations, which in turn reduces the cir-clips' tensioning power. The rings can thenbecome loose and damage the piston.

Foreign objectsEverything other than clean air and pure fuel that enters the engine's inlet port causessome type of abnormal wear or damage to the cylinder and piston.

This type of increased wear shows on the piston's inlet side starting at the lower edgeof the piston skirt.

The damage is caused by badly filtered air that passes through the carburettor and intothe engine.

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6

505 69 85-70

Cylinder and piston

Inlet side.

Particles of dust and dirt from carbon-likedeposits on the top of the piston and in thepiston ring groove. The piston ring sits firmlyin the groove. Piston material has beenworn away.

The lower part of the piston skirt is thinner onthe inlet side than on the exhaust side.

The piston scored and worn from the pistonring down on the inlet side.

Extensive damage to the piston's inlet side..

Action:Fit a finer grade filter.

Check the filter carefully for holes anddamage after cleaning. Replace the filterif necessary.

Clean more carefully and use the rightcleaning agent (e.g. tepid soapy water orHusqvarna Active Cleaning).Change the filter.

Fit the filter correctly.

Fit a new air filter.

Cause:● Faulty air filter. Small dust particles

pass through the filter.

● The filter is worn out due to too muchcleaning, whereby small holes haveappeared in the material.

● Unsuitable filter maintenance, e.g.wrong method or wrong cleaningagent. Flock material becomes looseand holes appear.

● Air filter incorrectly fitted.

● Air filter damaged or missing.

Large, softer particles that penetrate into the engine cause damage to the piston skirtunder the piston ring as the photograph shows.

Cause:● Air filter incorrectly fitted.

● Air filter damaged or missing.

Action:Fit the filter correctly.

Fit a new air filter.

Larger, harder particles that enter the engine cause serious damage to the undersideof the piston skirt.

Cause:● Air filter damaged or missing.

● Parts from the carburettor or intakesystem have become loose and en-tered the engine.

Action:Fit a new air filter.

Regular service and inspection.

144

6 Cylinder and piston

Defect:Broken cooling fins, damaged threads or sheared bolts bythe exhaust port.

Seizure marks in the cylinder bore (especially by the exhaustport).

Surface coating in the cylinder bore worn out (primarily at thetop of the cylinder).

The piston shows signs of seizure score marks.

Piston ring burnt in its groove.

Service advice

Action:In bad situations – replace the cylinder.Repair the threads using Heli-Coil.

Polish the damaged area using a fine grade emery cloth sothat the coating of aluminium disappears.With deep seizure score marks the piston and cylindershould be replaced.

Replace the cylinder and piston.

Carefully polish the damaged area using a fine file of finegrade emery cloth. Before the piston is refitted the cylindershould be polished as above. With deep score marks thepiston and cylinder should be replaced.

Carefully loosen the piston ring and clean the groove wellbefore refitting. Carbon deposits in the groove impair theimportant heat transfer between the piston and cylinder.

Check the wear on the piston ring by placing it in the lowerpart of the cylinder.

Wear tolerancesCylinder bore Piston ring gap Piston ring groove Piston ring play

When the surface coating isworn and aluminium appears.

Max. 1.0 mm with the pistonring inserted in the lower part ofthe cylinder.

Max. height on a new pistonring + 0.10 mm.

Max. 0.15 mm. Clean the groovecarefully before measuring.

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6

Mondo

122L

Mondo Max

225L/LD

232L

Mondo Mega

225R/RD

232R

322

325

235R

240R

245R

250R

245RX

250RX

252RX

265RX

240RBD

235P

250PS

225E

18H

225H60/75

140B/141B

132HBV

225BV/225HBV

24.0 34.5 26.4

22.5 32.0 28.0

24.0 34.5 26.4

25.4 34.0 28.0

30.8 35.0 32.0

24.0 34.5 26.4

25.4 34.0 28.0

30.8 35.0 32.0

21.7 32.0 27.0

24.5 34.0 27.0

36.3 38.0 32.0

40.2 40.0 32.0

44.3 42.0 32.0

48.7 44.0 32.0

44.3 42.0 32.0

48.7 44.0 32.0

50.8 45.0 32.0

65.1 48.0 36.0

36.3 38.0 32.0

36.3 38.0 32.0

48.7 44.0 32.0

25.4 34.0 28.0

18.0 29.5 26.4

25.4 34.0 28.0

40.2 40.0 32.0

31.7 36.9 30.2

25.4 34.0 28.0

Cylinder and piston

Technical data

Model Displacement Cylinder diameter Strokecm3 mm length mm

146

147

7.Crankshaft and crankcase

ContentsReplacing the sealing ring ignition side

Models 265, 250, 250PS __________________________ 148

Replacing the sealing ring clutch side

Models 265, 250, 250PS __________________________ 150

Replacing the vibration damper

Mod. 250 _______________________________________ 152

Dismantling/Assembling the crankcase

Model 265 ______________________________________ 152

Model 250 ______________________________________ 154

Models 250, 250PS ______________________________ 155

Inspecting the crankshaft ________________________ 157

Dismantling/Assembling the crankshaft

Models 240/245 _________________________________ 158

Models 225/232/235 ______________________________ 160

Model 225HBV __________________________________ 162

Models 225AI15, 225AI25 _________________________ 163

Models 322, 325 _________________________________ 164

Dismantling/Assembling the crankcase

Model 122 ______________________________________ 164

Model 32 _______________________________________ 166

Model Mondo ___________________________________ 170

Model 18H _____________________________________ 173

Models 140B, 141B ______________________________ 174

Leakage testing the crankcase ____________________ 176

Husqvarna E-TECH ______________________________ 176

148

7

504 91 40-01

504 91 28-00

A

A

B

Crankshaft and crankcase

The crankshaft is journalled in the crankcase onheavy-duty ball bearings. In addition to thejournalling point for the crankshaft, the crankcaseacts as scavenging pump for the fuel/air mixturewhen this is “sucked” from the carburettor and isforced into the cylinder's combustion chamber.The crankcase must be perfectly sealed so as notto affect this pump function. There cannot be anyleakage either from the crankshaft or between thecrankcase halves or between the crankcase andthe cylinder.Always replace the sealing rings and gasketswhen servicing the crankcase.

The task of the crankshaft is to transfer the reciprocat-ing motion of the piston to rotation. To do this requiresa stable design withstanding immense pressure, rota-tional and bending strain as well as high rotationalspeed. In addition the connecting rod is exposed tolarge acceleration and retardation forces as it movesbetween top and bottom dead centres. This puts spe-cial demands on the bearings that must withstandquick changes in load. Besides, the bearing's rollerretainer also must cope with high temperatures andfriction. Therefore it is extremely important when serv-icing, to check the roller retainer for cracking, wear andmiscolouration due to overheating.

Replace the sealing ring- ignition sideModel 265Dismantle the flywheel and ignition mod-ule.

Replace the sealing ring- ignition sideModel 265The sealing ring can be replaced withoutsplitting the crankcase.

Dismantle the flywheel.

Undo the six allen bolts (A) and loosenthe bolt (B) enough so that the ignitionmodule can be lifted out.

Dismantle the sealing ring with the puller. Screw on the puller 504 91 40-01 as far asit will go between the crankshaft and thesealing ring.

Pull the sealing ring out of the crankcase.

Lubricate the shaft extension and fit anew sealing ring.

Lubricate the shaft extension with a fewdrops of engine oil and place a new seal-ing ring in position with the metal coverfacing outwards.

Press in the sealing ring until it is levelwith the crankcase.

Use e.g. punch 504 91 28-00.

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7

504 90 00-04

505 38 17-09

504 91 28-06

Crankshaft and crankcase

Fit a new sealing ring.

Check that the O-ring is not damaged andfit the holder.

Fit a new sealing ring.

Turn the sealing ring so that the metalcover faces outwards.

Use a suitable punch, e.g. 504 91 28-06.

Check that the O-ring between the sealholder and the bearing in the crankcase isnot damaged.

Change the O-ring if it does not seal asintended.

Lubricate the crankshaft and fit the holder.

Remove the sealing ring from the holder. Remove the sealing ring from the holderusing punch 505 38 17-09.

Use a suitable tubular sleeve as a drift.

Remove the seal holder. Press out the seal holder by using ascrewdriver.

Model 250Dismantle the flywheel and the washerover the sealing ring.

Model 250Dismantle the covers and ignition systemincl. the flywheel. See chap. “Ignition sys-tem”.

Remove the three bolts holding the washerover the seal holder.

Use allen key 504 90 00-04.

150

7

A

505 38 17-09

505 26 79-12

Crankshaft and crankcase

Model 250PSDismantle the fuel tank.

Model 250PSFirst dismantle the fuel tank, which isplaced outside of the starter.

Remove the 4 screws (two on each side)holding the tank on the crankcase.

Dismantle the cylinder cover, starter andflywheel.

Let the tank remain suspended by thefuel hose.

Dismantle the cylinder cover.

Remove the screws and lift off the starter.

Dismantle the flywheel by using the pushbar no 505 26 79-12.

The sealing ring is now accessible forreplacement in the same way as de-scribed for model 250.

Replacing the sealingring - clutch sideModel 265Dismantle the centrifugal clutch so thatthe sealing ring is accessible.

Remove the seal holder and change thesealing ring.

Replacing the sealingring - clutch sideModel 265The sealing ring can be changed withoutsplitting the crankcase.

Dismantle the clutch and remove thespacer (A).

Undo the three bolts that hold the coverover the seal holder.

Remove the seal holder and replace thesealing ring as described for model 250(ignition side).

Take out the sealing ring from the holder. Take out the sealing ring from the holderusing punch 505 38 17-09.

Use a suitable tubular sleeve as a drift.

151

504 91 40-01

504 91 28-06

7

504 91 28-00

Crankshaft and crankcase

Model 250PSDismantle the hydraulic oil tank, theadapter between the engine body and thehydraulic oil tank and the clutch.

Now replace the sealing ring in the sameway as described for model 250.

Model 250PSDismantle the hydraulic oil tank from theengine body. See chapter “Centrifugalclutch”.

Remove the clutch.

See chapter “Centrifugal clutch”.

Dismantle the adapter between the en-gine body and the hydraulic oil tank byremoving the 4 screws.

Now replace the sealing ring in the sameway as described for model 250.

Lubricate the shaft extension with a fewdrops of engine oil and place a newsealing ring in position with the metalcover facing outwards. Press in the seal-ing ring until it is level with the crankcase.

Use e.g. punch 504 91 28-00.

Lubricate the shaft extension and fit anew sealing ring.

Model 250Dismantle the clutch so that the sealingring is accessible.

Dismantle the sealing ring using a puller.

Model 250Dismantle the clutch. See chap. “Cen-trifugal clutch”.

Screw on the puller 504 91 40-01 as far asit will go between the crankshaft and thesealing ring.

Thereafter pull the sealing ring out of thecrankcase.

Fit a new sealing ring.

Check whether the O-ring is damagedand fit the holder.

Fit a new sealing ring in the holder.

Turn the sealing ring so that the metalcover faces outwards.

Use a suitable punch, e.g. 504 91 28-06.

Check that the O-ring between the sealholder and the bearing in the crankcase isnot damaged.

Change the O-ring if it does not seal asintended.

Lubricate the crankshaft and fit the holder.

152

502 51 61-01

7

504 90 00-04

502 50 66-02

Crankshaft and crankcase

Replacing the vibrationdamperModel 250Use tool no. 502 50 66-02 to dismantle /assemble the rubber vibration dampersto avoid damaging them.

Replacing the vibrationdamperModel 250Dismantle the cylinder cover and clutchhousing/shaft. Also see chap. “Centrifu-gal clutch”.

Use tool no. 502 50 66-02 to dismantle/assemble the rubber vibration dampers.

Use an allen key to dismantle the springtype vibration damper.

If the vibration damper is of a spring typeuse an allen key no. 504 90 00-04 todismantle.

Stripping the crankcaseModel 265Dismantle all parts so only the crankcaseand crankshaft remain.

Remove the crankcase bolts.

Stripping the crankcaseModel 265Dismantle all parts so only the crankcaseand crankshaft remain.

See respective chapters.

Remove the 5 bolts holding the crank-case halves.

Separate the crankcase halves. Place the puller 502 51 61-01 on theclutch side's crankcase half and separatethe two halves.

NOTE!

Make sure the tool also gripsunder the metal washer on thedamper. Otherwise the rubbermust absorb all the turning forceand can be damaged.

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7

502 51 61-01

504 91 28-00

502 50 30-08

502 50 30-08

Crankshaft and crankcase

Fit the crankshaft in the ignition side'scrankcase half.

Carefully heat the ignition side's crank-case half to 150 – 200°C and position thecrankshaft.

Assembling thecrankcaseModel 265Clean all components before assembly.

Check the crankshaft with regard to wearand damage. See section “Inspecting thecrankshaft”.

Fit the bearing on the crankshaft.

Use assembly tool 502 50 30-08 on theignition side.

Assembling thecrankcaseModel 265Clean all components and fit the bearingon the crankshaft.

Carefully heat the crankcase halves to150 – 200°C using a hot air gun.

Dismantle the bearing by using a punchor by hitting the crankcase halve againsta wooden block until the bearing falls outof its seating.

Press out the sealing rings from the crank-case halves on ignition and clutch sides.

Remove the bearings and sealing ringsfrom the crankcase halves.

Use the same puller and press the crank-shaft out of the ignition side's crankcasehalf.

Press out the crankshaft.

Use assembly tool 502 50 30-08 if neces-sary.

NOTE!

Insert the crankshaft correctly. Theshaft extension with the taper isthe ignition side.

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7

502 50 53-01

502 50 30-08

Crankshaft and crankcase

Stripping the crankcaseModel 250Dismantle all parts so only the crankcaseand crankshaft remain.

Remove the crankcase bolts.

Stripping the crankcaseModel 250Dismantle all parts so only the crankcaseand crankshaft remain.

Remove the 7 bolts holding the crank-case halves.

See respective chapters.

Fit new sealing rings to both the ignitionand clutch sides.

Place assembly sleeve 502 50 53-01 onthe clutch side's shaft extension to protectthe sealing ring when its fitted.

Fit new sealing rings and the remainingcomponents.

Tighten all the crankcase bolts cross-wise.

Cut off any excessive gasket from thecylinder base surface.

Rotate the crankshaft by hand. If it runstightly apply a few light blows to the shaftextensions using a plastic mallet so thatthe stress releases and the shaft rotateseasily.

Tighten all the crankcase bolts.

Check that the crankshaft rotates easily.

Fit the drive side's crankcase half.

Make sure that the gasket is not mis-aligned.

Place the gasket in position on the igni-tion side's crankcase half. Attach using alittle grease.

Heat the clutch side's crankcase half to150 – 200°C and place over the crank-shaft.

Use assembly tool 502 50 30-08 if neces-sary.

Tip!It is recommended that the crankcasebolts are inserted to guide the gasketbefore the crankcase half is fully installed.

NOTE!

Do not forget the O-ring betweenthe bearing and the sealing ring.

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7

502 51 61-01

502 51 61-01

504 91 28-06

502 50 30-09

Crankshaft and crankcase

Separate the crankcase halves usingpuller no. 502 51 61-01.

Separate the crankcase halves usingpuller no. 502 51 61-01.

Press out the crankshaft from the crank-case half using puller no. 502 51 61-01.

Press out the crankshaft from the crank-case half using puller no. 502 51 61-01.

Dismantle the bearings from the crank-case halves.

Carefully heat the crankcase halves toabout 150°C.

Dismantle the bearing using a punch orby hitting the crankcase half against awooden block until the bearing falls out ofits seating.

Press out the sealing ring from the clutchside's crankcase half.

Assembling thecrankcaseModel 250Clean all components and fit the bearingon the crankshaft.

Assembling thecrankcaseModel 250Clean all components before assembly.

Check the crankshaft with regard to wearand damage.

See section “Inspecting the crankshaft”.

Fit the bearing on the crankshaft.

Use assembly tool no. 502 50 30-09 (M8).

156

7

502 50 30-07

Crankshaft and crankcase

Fit crankshaft on the clutch side's crank-case.

Carefully heat the clutch side's crank-case to about 150°C and position thecrankshaft.

Fit the ignition side's crankcase half.

Make sure that the gasket is not mis-aligned.

Heat the ignition side's crankcase half(approx. 150°C).

Place the gasket in position on the driveside's crankcase half.

Attach using a little grease.

If necessary use assembly tools no.502 50 30-07 + 502 50 30-09.

Tip!It is recommended that the crankcasebolts are inserted to guide the gasketbefore the crankcase half is fully installed.

Tighten all the crankcase bolts.

Check that the crankshaft rotates easily.

Fit new sealing rings and the remainingcomponents.

Tighten all the crankcase bolts crosswisestarting closest to the crankshaft.

Cut off any excessive gasket from thecylinder base surface.

Rotate the crankshaft by hand. If it runstightly apply a few light blows to the shaftextensions using a plastic mallet so thatthe stress releases and the shaft rotateseasily.

Fit new sealing rings to both the ignitionand clutch sides as previously described.

Lubricate the crank bearing and the mainbearing with a few drops of oil before thepiston and cylinder are fitted.

Fit the remaining components.

Model 250PSScrew the hydraulic oil tank adapter in theengine body.

Place the hose clip on the adapter.

Model 250PSScrew the hydraulic oil tank adapter in theengine body.

Place the hose clip on the adapter so thelittle tab enters the hole in the adapter.Only tighten the hose clip so that it cannotbe turned. This facilitates the assembly ofthe hydraulic oil tank.

NOTE!

Turn the crankshaft the right way.The shaft extension without thekeyway on the clutch side.

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7Crankshaft and crankcase

Check the main bearing. Check the main bearing. There should beno radial (up and down) play on the con-necting rod.

However, there should be axial play, i.e. toprovide good lubrication to the main bear-ing.

Check the connecting rod's little end. Check the little end on the connecting rod.

If there are signs of seizure, discolourationin the bearing race the crankshaft shouldbe replaced.

Inspecting thecrankshaftGeneralCheck the connecting rod's big end.

Inspecting thecrankshaftGeneralThe crankshaft cannot be renovated butmust be replaced with a new one if it isworn or damaged.

Check the big end on the connecting rod.If there are signs of seizure, discolourationon the sides or damage to the needleseating the crankshaft should be replaced.

Slide the hydraulic oil tank in the adapteras far as it will go and then turn it anti-clockwise. (Bayonet fitting).

Tighten the hose clip.

Slide the hydraulic oil tank in the adapteras far as it will go and then turn it anti-clockwise. (Bayonet fitting).

Tighten the hose clip.

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7

504 90 90-01

505 38 17-09

Crankshaft and crankcase

Dismantling thecrankshaftModels 240/245Dismantle all the components surround-ing the crankcase including the cylinderand piston.

See respective chapters.

Lift out the crankshaft complete with bear-ings and bearing retainer from the crank-case.

Dismantling thecrankshaftModels 240/245Dismantle the crankshaft from the crank-case.

Remove the bearing seats from the bear-ings.

Pull apart the bearing seat halves andremove them from the bearings using ascrewdriver.

Dismantle the bearings from the crank-shaft.

Dismantle the bearings from the crank-shaft using puller no. 504 90 90-01.

Dismantle the sealing rings. Press out the bearing rings from the bear-ing seats by using punch no. 505 38 17-09.

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7

502 50 30-10

504 91 28-06

Crankshaft and crankcase

Lubricate the shaft extensions with a fewdrops of oil and fit the bearing seats ontothe bearings.

Turn the seats so they lock into eachother.

Fit new sealing rings in the bearing re-tainer using punch no. 504 91 28-06.

Fit new sealing rings in the bearing re-tainer.

Fit the bearing on the crankshaft. Fit the bearing on the crankshaft's igni-tion side using assembly tool no.502 50 30-10.

Now fit the bearing on the crankshaft'sclutch side in the same way.

Assembling thecrankshaftModels 240/245Check the crankshaft as set out in thesection “Inspecting the crankshaft”.

Clean the crankcase's contact faces care-fully removing sealant residue and grease.

Carefully use a screwdriver or flat scraperso as not to scratch the faces.

Assembling thecrankshaftModels 240/245Check the crankshaft as set out in thesection “Inspecting the crankshaft”.

Clean the crankcase's contact faces.

NOTE!

Turn the sealing rings so that themetal cover faces outwards fromthe engine.

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7

503 26 70-01

Crankshaft and crankcase

Place the crankshaft in the crankcase.

Use sealant no. 503 26 70-01.

Check that the contact faces on the bear-ing seats and crankcase are free of grease.

Apply a thin string (1–1.5 mm) of sealant(503 26 70-01) to the crankcase contactfaces.

Fit the piston and cylinder. Check that the contact faces on the cylin-der are free of grease.

Fit the piston and cylinder.

See chapter “Cylinder and piston”.

Dismantling thecrankshaftModels 225/232/235Lift out the crankshaft from the crank-case.

Dismantling thecrankshaftModels 225/232/235Dismantle all the components surround-ing the crankcase including the cylinder.

See respective chapters.

Lift out the crankshaft complete with bear-ings from the crankcase.

Dismantle the piston and pull off the bear-ings from the shaft extensions.

Dismantle the piston.

Pull off the bearings from the shaft exten-sions by hand.

Position the crankshaft.

Make sure it is facing the right way!

NOTE!Only this sealant must be used.

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7Crankshaft and crankcase

Position the crankshaft in the crankcase. Position the crankshaft in the crankcase.

Assembling thecrankshaftModels 225/232/235Check the crankshaft as set out in thesection “Inspecting the crankshaft”.

Fit the bearing on the crankshaft.

Fit the piston.

Assembling thecrankshaftModels 225/232/235Check the crankshaft as set out in thesection “Inspecting the crankshaft”.

Lubricate the crankshaft's shaft exten-sions using a few drops of oil and slide thebearing on by hand.

Fit the piston on the connecting rod.

Fit a new seal on the bearing. Press a new seal on the bearing by usinga punch that presses against the sealingring's outer edges.

Always replace the seals.

Remove the old seal from the bearing bycutting a slot in the elastic casing andmetal cup using a hacksaw.

Now pry the seal from the bearing usinga screwdriver.

Remove the seals from the bearing.

NOTE!

Turn the piston the right way. Thearrow facing the exhaust port.

NOTE!

No sealant is required in thebearing seatings.

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7

503 26 70-01

504 91 06-05

Crankshaft and crankcase

Fit the cylinder. Make sure the contact faces on the cylin-der and crankcase are clean from sealantand grease.

Apply a thin string (1–1.5 mm) of sealantto the bottom of the cylinder and fit thecylinder.

See chap. “Cylinder and piston”.

Dismantling/assemblingthe crankshaftModel 225HBVDismantle the lower half of the blowerunit.

Remove the steel rail.

Dismantling/assemblingthe crankshaftModel 225HBVRemove all screws (11) holding the lowerhalf of the blower unit and lift off this.

Remove the steel rail.

Dismantle the blades and impeller. Replace the spark plug with piston stopno 504 91 06-05.

Unscrew the centre nut and lift off theblades and impeller.

Dismantle the upper half of the blowerunit and lift off the cover over the handle.

Remove the 4 screws (2 on each side)holding the upper half of the blower unit.

Lift off the cover over the handle.

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7Crankshaft and crankcase

Dismantling/assemblingthe crankshaftModels 225AI15, 225AI25Dismantle the gearbox from the enginebody.

Dismantle and assemble the crankcasein the same way as described for models225/232/235.

Dismantling/assemblingthe crankshaftModels 225AI15, 225AI25Remove the 6 screws holding the gear-box on the engine body and lift off thegearbox.

Dismantle all components around thecrankcase and dismantle and assemblethe crankshaft in the same way as de-scribed for models 225/232/235.

Dismantle and assemble the crankcasein the same way as described for models225/232/235.

Dismantle and assemble the crankcasein the same way as described for models225/232/235.

Separate the engine body and handlepart and dismantle all components aroundthe crankcase.

Remove the 4 screws.

Separate the handle part and engine body.

Dismantle all components around thecrankcase. See respective chapters.

Remove the 2 bolts holding the handle onthe crankcase.

Remove the 2 bolts holding the handle onthe crankcase.

Do not forget the spacer nut that shouldlie closest to the crankcase!

NOTE!

Check when assembling that thethrottle cable and short-circuitcable are not pinched.

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7 Crankshaft and crankcase

Stripping the crankcaseModel 122Dismantle all parts so only the crankcaseand crankshaft remain.

Remove the crankcase bolts.

Stripping the crankcaseModel 122Dismantle all parts so only the crankcaseand crankshaft remain.

See respective chapters.

Remove the 3 bolts holding the crank-case halves.

Assembling thecrankshaftModels 322, 325Check the crankshaft as set out in thesection “Checking the crankshaft”.

Clean the contact surfaces on the crank-case.

Fit new bearings on the crankshaft withthe open side facing in towards the crankdisc.

Lubricate the big-end bearing with a fewdrops of engine oil and position the crank-shaft in the crankcase.

Assemble all the remaining parts in thereverse order as set out for dismantling.

See respective sections if necessary.

Leakage test the crankcase according tothe instructions in the section “Leakagetesting the crankcase”.

Dismantling thecrankshaftModels 322, 325Dismantle all components so that onlythe crankcase and crankshaft remain.

Now lift the crankshaft out of the crank-case.

Dismantling thecrankshaftModels 322, 325Dismantle all components so that onlythe crankcase and crankshaft remain.

See respective sections for detailed infor-mation if necessary.

Now lift the crankshaft out of the crank-case.

Remove the bearing (sliding fit) and thespacer washers.

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7

505 38 17-09

Crankshaft and crankcase

Separate the crankcase halves using ascrewdriver.

Insert a wide blade screwdriver in be-tween the raised sections on the crank-case halves and pry open the crankcase.

Lift out the crankshaft.

Dismantle the bearing. Carefully heat the crankcase halves us-ing a hot air gun to approx. 150°C.

Dismantle the bearing using a punch orby hitting the crankcase half against awooden block until the bearing falls out ofits seating.

Dismantle the sealing rings. Press out the ignition side's sealing ringusing a punch.

Let the circlip between the bearing andsealing ring remain in the crankcase half.

Press out the sealing ring from the clutchside's crankcase half.

Assembling thecrankcaseModel 122Clean all components.

Inspect the crankshaft with regard to wearand damage.

Fit new sealing rings in the crankcasehalves.

Assembling thecrankcaseModel 122Clean all components.

Check the crankshaft according to sec-tion “Inspecting the crankshaft”.

Fit new sealing rings in the crankcasehalves using suitable punches, e.g.505 38 17-09 for the clutch side.

Press in the sealing rings level with thecrankcase.

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7

503 26 70-01

Crankshaft and crankcase

Fit the bearings in the crankcase halves. Heat the crankcase halves to about 150°Cusing a hot air gun and position the bear-ings.

Make sure they sit against the circlip orthe stop in the bearing seat.

Position the crankshaft on the ignitionside's crankcase half and apply a thinstring of sealant to the contact face.

Position the crankshaft on the ignitionside's crankcase half.

Check that the contact faces on the crank-case halves are free from grease and oldgasket residue.

Apply a thin string (1 – 1.5 mm) of sealant503 26 70-01 on the crankcase halves'contact faces.

Fit the clutch side's crankcase half andtighten the crankcase bolt.

Slide the clutch side's crankcase halfover the crankshaft by hand and tightenthe 3 crankcase bolts.

Assemble the remaining parts in the re-verse order set out for dismantling.

Stripping the crankcaseModel 32Dismantle all parts so only the crankcaseand crankshaft remain.

Dismantle the throttle cable and its holder.

Stripping the crankcaseModel 32Dismantle all parts so only the crankcaseand crankshaft remain.

See respective chapters.

Remove the screw and plastic compo-nents that hold the throttle so the crank-case bolts are accessible.

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7

21

Crankshaft and crankcase

Check the reed valve (1) and movementlimiter (2) with regard to wear and dam-age.

Inspect the reed valve (1). If it is cracked,worn or shows signs of corrosion it shouldbe replaced.

Also check the movement limiter (2) withregard to wear and damage.

Dismantle the intake valve. Remove the 2 bolts holding the intakevalve.

Carefully separate the halves. Carefully separate the halves.

Use a screwdriver to facilitate separatingas sealant has been used on both sides ofthe gasket.

Remove the bolts holding the crankcasehalves together.

Remove the 6 bolts holding the crank-case halves together.

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7

B

A

Crankshaft and crankcase

Check the contact face on the intakemanifold.

Check the contact face on the intakemanifold.

It is extremely important for the engine'slow speed characteristics that the reedvalve seals correctly against the intakemanifold.

Lift out the connecting rod complete withpiston.

Lift out the connecting rod complete withpiston.

Note which way the connecting rod wasfacing. The connecting rod bearing withthe small insertion spacing should facethe crank disc.

Clean off any gasket or sealant residuefrom the crankcase half.

Remove the key and circlip. Remove the key (A) using side cuttersand the circlip (B).

Knock out the crankshaft from the crank-case using a plastic mallet.

Screw on the flywheel nut on the crank-shaft and knock out the shaft using aplastic mallet.

Place a block of wood under the crank-case so the crankshaft comes free.

NOTE!

Check when assembling that thereed valve is in the centre of theintake manifold.

NOTE!

Turn the crankshaft so that thecrank disc does not hit thecrankcase.

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7

504 91 28-00

Crankshaft and crankcase

Heat the crankcase and fit the inner bear-ing.

Heat the crankcase using a hot air gun toapprox. 150°C and position the inner bear-ing. Adjust if necessary using punch no.504 91 28-00 so the bearing rests againstthe circlip.

Assembling thecrankcaseModel 32Fit a new sealing ring in the crankcase.

Fit the circlip.

Assembling thecrankcaseModel 32Fit a new sealing ring. Turn it so thescraper edge faces inwards and press itinto place against the circlip using a suit-able punch and hammer.

Fit the circlip and make sure it sits cor-rectly in its groove.

Dismantle the sealing ring. Remove the circlip on the ignition side (letthe other circlip remain in place) andpress out the sealing ring using a punchand hammer.

Dismantle the bearing. Heat the crankcase to approx. 150°C us-ing a hot air gun and dismantle the bear-ing by knocking the crankcase against awooden block.

Use a suitable punch and hammer if nec-essary.

170

A

7 Crankshaft and crankcase

Grease and position the outer bearing.

Make sure the dust seal faces outwards.

Turn the crankcase while its still warmand position the outer bearing.

Fit the crankshaft in the crankcase.

Fit the circlip on the crankshaft.

Fit the crankshaft while the crankcaseand bearing are still warm.

Press in the crankshaft using a suitablebrass punch and hammer.

Check that the shaft can rotate freely andfit the circlip on the shaft.

Fit the connecting rod on the crank pin. Fit the connecting rod on the crank pin.

Stripping the crankcaseModel MondoDismantle all parts so only the crankcaseand crankshaft remain.

Remove circlip (A).

Stripping the crankcaseModel MondoDismantle all parts so only the crankcaseand crankshaft remain.

See respective chapters.

Remove circlip (A).

NOTE!

Turn the connecting rod so itcomes as close to the bearing aspossible.

Assemble the remainingcomponents in the reverse orderset out for dismantling.

NOTE!

Grease using bearing grease andfit it with the dust seal facingoutwards.

Make sure the bearing is sittingagainst the circlip.

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7Crankshaft and crankcase

Knock the crankshaft out of the crank-case using a plastic mallet.

Screw the flywheel nut on the crankshaftand knock out the shaft using a plasticmallet.

Dismantle the bearing on the ignition side. Heat the crankcase to approx. 150°C anddismantle the bearing on the ignition sideby knocking the crankcase against awooden block.

Dismantle the other bearing inwards. Dismantle the other bearing inwards.

You may need to knock out the bearingusing a punch.

Dismantle the circlip on the ignition sideand knock out the sealing ring.

Dismantle the circlip on the ignition side,but let the circlip on the other side of thesealing ring remain in place.

Knock out the sealing ring using a suit-able punch and hammer.

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7

504 91 28-00

Crankshaft and crankcase

Assembling thecrankcaseModel MondoFit a new sealing ring in the crankcase.

Fit the circlip.

Assembling thecrankcaseModel MondoFit a new sealing ring in the crankcase.Turn it so the scraper edge faces inwards.

Fit the circlip and make sure it sits cor-rectly in its groove.

Grease and fit the bearing in the crank-case.

Lubricate the bearing with grease.

Carefully heat the crankcase and fit thebearing in the crankcase.

Use punch no. 504 91 28-00 to press thebearing level with the crankcase.

Grease and fit the dust sealed bearingwhile the crankcase is still warm.

Grease the dust sealed bearing and posi-tion it while the crankcase is still warm.

Fit the crankshaft in the crankcase. Lubricate the crankshaft with a few dropsof oil and slide it in the bearing.

Use a hammer and suitable punch topress the shaft down towards bearing.

NOTE!

The dust sealed side of thebearing should face outwards.

Make sure the bearing restsagainst the circlip.

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7Crankshaft and crankcase

Dismantle the crankshaft from the crank-case.

Dismantle the bearing and sealing rings.

Place a wooden block under the crank-case and press out the crankshaft byusing a plastic hammer.

Remove the circlip. Remove the circlip on the spindle usingcirclip pliers.

Dismantling thecrankcaseModel 18HDismantle all components so that onlythe crankcase and crankshaft remain.

See respective chapters if necessary.

Dismantling thecrankcaseModel 18HDismantle all components so that onlythe crankcase and crankshaft remain.

Remove the cover over the crankcase.

Check that the crankshaft can rotate freelyand fit the circlip.

Check that the crankshaft can rotate freely.

Lightly knock the shaft extension with aplastic hammer until the crankshaft ro-tates freely.

Fit the circlip and the remaining compo-nents in the reverse order set out fordismantling.

Remove the cover over the crankcase.Carefully pry up with a screwdriver. Seal-ant has been used on both sides of thegasket.

NOTE!

Mark which end of the crankshaftshould face the piston.

Dismantle the bearings and sealing ringsin the same way as described for model32.

NOTE!

Turn the crankshaft so that thecrank disc does not hit thecrankcase.

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7

503 26 70-01

Crankshaft and crankcase

Remove the key in the crankshaft and the4 crankcase bolts.

Lift off the fan side crankcase half.

Remove the key in the crankshaft and thefour screws holding together the crank-case halves.

Lift off the fan side crankcase half.

Dismantling thecrankcaseModels 140B, 141BDismantle all components so that onlythe crankcase and crankshaft remain.

Dismantling thecrankcaseModels 140B, 141BDismantle all components so that onlythe crankcase and crankshaft remain.

See respective chapters if necessary.

TIP!Note which way, e.g. the muffler is fitted toavoid uncertainty when assembling.

Fit the piston on the connecting rod andthe remaining parts in the reverse orderas set out for dismantling.

Fit the piston on the connecting rod sothat the piston ring’s locking pin comesopposite the inlet port on the cylinder.

Assemble remaining parts in the reverseorder as set out for dismantling.

Assembling thecrankcaseModel 18HFit a new sealing ring and circlip in thecrankcase.

Fit the crankshaft’s bearing

Fit the crankshaft in the crankcase andthe circlip on the crankshaft.

Fit the connecting rod on the crankshaftjournal.

Assembling thecrankcaseModel 18HFit a new sealing ring in the crankcase.

Fit the circlip and check that it lies cor-rectly in its groove.

Fit the crankshaft’s bearing.

Fit the crankshaft in the crankcase andthe circlip on the crankshaft.

Fit the connecting rod on the crankshaftjournal. Turn it so that the marked endfaces towards the piston.

Assembly takes place in the same way asdescribed for model 32.

NOTE!

Use sealant on both sides of thegasket on the cover over thecrankcase.

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7

504 90 00-03 502 50 70-01

502 51 61-01

Crankshaft and crankcase

Dismantling the crankshaft.

Dismantle the bearing and sealing rings.

Press out the crankshaft from the starterside’s crankcase half using puller no. 50251 61-01.

Dismantle the bearing and sealing ringsafter the crankcase half has been heatedto approx. 150°C using a hot air gun.

Assembling thecrankcaseModels 140B, 141BHeat the crankcase halves and positionthe bearing.

Fit the sealing rings.

Fit the crankshaft in the starter side’scrankcase half.

Assembling thecrankcaseModels 140B, 141BHeat the crankcase half to approx. 150°Cusing a hot air gun and position the bear-ing.

Fit the sealing rings with the metal casefacing outwards.

Fit the crankshaft in the starter side’scrankcase half before the bearing hastime to cool.

Position the fan side’s crankcase half andtighten the 4 crankcase bolts.

Fit the piston with the locking pin facingthe exhaust port on the cylinder.

Place a new crankcase gasket in posi-tion. Secure it with a little grease so itdoes not slide out of position.

Position the fan side’s crankcase half andtighten the 4 bolts.

Fit the piston so that the locking pin facesthe exhaust side of the cylinder.

Assemble remaining parts in the reverseorder as set out for dismantling.

NOTE!

Do not forget the spacer washerbetween the crankshaft and thebearing.

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7

502 50 38-01 502 50 37-01

502 54 11-01 503 84 40-01

A

BA

+ –

Crankshaft and crankcase

Leakage testing thecrankcaseFit the two sealing plates (A) and testpressure nipple (B).

Leakage testing thecrankcaseFit a sealing plate (A) no. 502 54 11-01between the carburettor and the intakemanifold and a plate between the cylin-der and the muffler.

Fit the test pressure nipple (B) no.503 84 40-01 in the spark plug hole.

Connect the pressure gauge or vacuumgauge and check for leakage.

Connect the pressure gauge 502 50 38-01to the nipple and pump a pressure of50 kPa (0.5 kp/cm2) in the crankcase.

Max. permitted leakage:20 kPa (0.2 kp/cm2) per 30 seconds.

Connect the vacuum gauge 502 50 37-01to the nipple and lower the pressure inthe crankcase to 50 kPa (0.5 kp/cm2).

Max. permitted leakage:

20 kPa (0.2 kp/cm2) per 30 seconds.

Any leakage can be difficult to localise ifthe crankcase is depressurised.

When leakage has been established witha vacuum, you can apply a slightoverpressure (0.1–0.3 kp/cm2) and at thesame time apply a layer of thin oil on thejoints and the sealing ring’s contact sur-faces on the crankcase to make leakdetection easier. Bubbles clearly markthe position of the leakage.

NOTE!

When pressurising the crankcase,leakage can occur on the inductionmanifold on those models thathave a rubber induction manifoldeven if the limit of 0.5 kp/cm2 is notexceeded. Let the sealingcompound (Silicone) cure beforethe crankcase is pressurised ordepressurised.

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7Crankshaft and crankcase

Adjustable fuel needleswith movement limiters

Fuel consisting of:Hydrocarbon (fuel)Two-stroke oil (2%)

What makes the E-TECH engine designunique is not a specific design solutionbut rather several solutions interacting toreduce flushing losses in the engine.

The carburettor’s job is to mix the air andfuel in the right proportions to give acombustible mixture, irrespective of thespeed and work load. The carburettor’sadjustable needles have been fitted withmovement limiters to prevent the enginefrom being run with a too “rich” fuel/airmixture. (Also see chapter “Fuel sys-tem”).

Husqvarna E-TECHIn 1996 Husqvarna presented a new,improved two-stroke engine as a part ofthe company’s efforts to produce en-gines that emit smaller amounts of haz-ardous substances.

The new engine was given the designa-tion E-TECH and was first used in a newbrush cutter model.

More stringent environment regulationsin the USA, which primarily involve alowering of the hydrocarbons, nitrousoxides and carbon monoxide content,brought about the new engine design.

Environment degradation is reducedthrough decreasing the amount of unburntgases (flushing losses) in the exhaustfumes.

Comparisons between an E-TECH en-gine model 225 and the three year olderengine design model 125 show that theCO content has been halved and thehydrocarbons and nitrous oxide contentshave been reduced by close to 70%. Inaddition a powerful increase in output isgained.

Fuel/air mixtureconsisting of:92% air 8% fuel

Exhaust gasesconsisting of:Hydrocarbon (HC)Nitrous oxide (NO

x)

Carbon monoxide (CO)Carbon dioxide (CO

2)

Particles (PM)

Air consisting of:21% oxygen78% nitrogen 1% others

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7

AA

A B

Crankshaft and crankcase

Standard

Standard

Optimised

Optimised

The design of the flushing channels andflushing ports have a large effect on theflushing losses.

By finely adjusting the channels’ crosssection area and angle to the rear edge ofthe cylinder as well as modification of thechannel’s last upward section, flushingcan be made more efficient (preventing apart of the oxidising gases from passingdirectly out in the exhaust channel).

By reducing the area of the muffler’s dis-charge opening the counter pressure isincreased and a smaller amount of unburntexhaust fumes come out of the muffler.Oxidising gases that flow up from thecrankcase meet greater resistance fromthe exhaust fumes and a small amountreach the combustion chamber. A disad-vantage of the increased counter pres-sure is the engine output decreases.

The crankcase pressure has been in-creased in the E-TECH engine so that alarger amount of oxidising gases can bepumped through the flushing channels tocompensate for the output loss.

This has been achieved by filling the crank-shaft’s crank discs (A) to reduce the "dead"non active volume in the crankcase.

The consequence of a higher flush pres-sure is a more concentrated jet of oxidis-ing gas up in the combustion chambercompared with a lower flush pressure.

The result is more efficient combustionand less flushing losses.

A = Low crankcase pressure

B = High crankcase pressure

179

7The remaining flushing losses and other exhaustresidue are converted in the E-TECH engine’scatalytic converter muffler.

The metallic lightweight catalytic converter is de-signed around a special baffle plate of metal in themuffler.

The plate is covered with a catalytic agent andfitted with specific thermodynamic conditionalchannels and guides to give the best gas flow overthe catalytic agent.

Crankshaft and crankcase

180

181

8.Hydraulic unit

ContentsHydraulic pump, Dismantling, assembly, model 250PS _ 182

Test running ___________________________________ 184

Hydraulic pump, Dismantling, assembly, model 235P ___ 184

Control valve’s function, model 235 P ______________ 186

Replacing the clutch drum and bearing, model 235P __ 187

Capacity test, model 235P ________________________ 189

182

8 Hydraulic unit

NOTE!

The hydraulic pressure is high, and demandsimmense care if leakage around connections hasoccurred. Replace the gaskets and tighten theconnections immediately once a leakage has beendiscovered.Cleanliness is extremely important with all workon the hydraulic system.

Hydraulics is an ideal solution to get a long andflexible power transmission between the engineand the cutting equipment.This has been utilised on model 235P which isused for, e.g. tree pruning and on the pruning sawmodel 250PS. The power from the combustionengine is transferred to the hydraulic pump via acentrifugal clutch and from the pump to the cut-ting equipment via a flexible hydraulic hose.

Hydraulic pumpDismantling, assemblyModel 250PSDismantle the hydraulic oil tank from theengine unit and then the clutch drum.

Remove the cover on the tank and drainoff the hydraulic oil.

Hydraulic pumpDismantling, assemblyModel 250PSDismantle the hydraulic oil tank from theengine unit and then the clutch drum asdescribed in the chapter "Centrifugalclutch".

Remove the 4 screws and lift off the coveron the tank.

Drain off all the hydraulic oil.

Unscrew the upper quick coupling andpress the hydraulic oil hose in the tank.

Unscrew the upper quick coupling andpress the hydraulic oil hose in the tank.

Dismantle the diffuser. Remove the lower quick coupling and liftout the diffuser from the tank.

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8

AB

C

D

BGF

E

Hydraulic unit

Remove the axle from the pump housing.

Replace damaged parts and assemble inthe reverse order as set out for disman-tling.

Unscrew the hose from the hydraulic pumpand remove the 6 bolts holding the cover(A).

Remove the cover and both impellers (B).

Lift up the hydraulic pump together withthe cover disc from the tank.

Lift up the hydraulic pump together withthe cover disc from the tank.

Check that the rubber collar is undam-aged and keeps tight. Otherwise fit a newcollar.

Remove the engine adapter. Remove all 8 bolts holding the engineadapter on the hydraulic pump.

Start with the 4 inner bolts.

Note how the pins on the adapter areplaced (half past 1 resp. half past 7).

Remove the key (E) from the pump axle(F).

Heat the pump housing (G) using a hot airgun to approx. 120°C. Now press out theaxle with the bearing from the pump hous-ing.

Use a suitable punch and hammer toknock the sealing ring out of the pumphousing.

Replace damaged parts and assemble inthe reverse order as set out for disman-tling.

NOTE!

Note on which axle and in whatpump chamber in the cover thatresp. impellers are fitted so thatthese are given the sameplacement in subsequentassembly.

Remove the gear (C) and bearingsleeve (D).

184

8

MIN.

502 42 45-01

MAX.

Hydraulic unit

Check that the pump chambers are freefrom damage.

If this is not the case, replace bothimpellers and cover.

Assemble all remaining parts in the re-verse order as set out for dismantling.

Check that the pump chambers in thecover are not scratched. If this is not thecase, the cover and both impellers mustbe replaced.

The impellers must not show signs ofcracking or other damage. Replace bothimpellers at the same time if necessary.

Assemble all remaining parts in the re-verse order as set out for dismantling.

Make sure all hose connections are tight.

Fill with hydraulic oil to the correct level. Fill with hydraulic oil to the correct level.

Use oil of the quality ISO VG32 at airtemperatures under +20°C and ISO VG45at air temperatures above +20°C.

Test runningFit the test running hose no.502 42 45-01 on the upper and lowerquick couplings.

Make sure the couplings make correctly.

Start the engine and test the pruning saw.

Hydraulic pumpDismantling, assemblingModel 235PRemove the bolts and lift off the hydraulicpump.

Drain the hydraulic oil.

Hydraulic pumpDismantling, assemblingModel 235PThe hydraulic pump can be lifted off of theengine once the 4 bolts holding the pumpon the crankcase have been removed.

Remove the refill plug and drain the hy-draulic oil.

NOTE!

The oil’s flash point shouldexceed +160°C. The oil must notbe electrically conductive.

Check the oil level when themachine has been run for 2-3 minand fill with more oil so that thelevel lies between min. and max.on the oil dipstick if necessary.

WARNING!Never start the pruningsaw without the hydraulicoil tank and hoses fitted. Ifthe tank is not fitted thecouplings can becomeloose and cause personalinjury.

!

185

8

A

A

B

Hydraulic unit

Dismantle the control valve from the pumphousing. Note how it is mounted.

Mark on the pump housing where thecontrol valve was mounted. Also notewhich way the control valve is facing so itis fitted in the same position when reas-sembled.

Remove the bolt (B), the control valve andthe sealing washer.

Loosen the screws (A) and lift up thehydraulic pump and control valve.

Loosen the screws (A) and lift up thehydraulic pump and control valve.

Remove the screws and cover from thehydraulic pump.

Remove the 4 screws holding the coveron the hydraulic pump.

Make sure the pump rests on the engineconnection flange and carefully lift off thecover with a rocking action so that anyremaining oil does not run out.

Remove the gasket between the coverand tank.

Unscrew the quick connector from thehydraulic hose.

Unscrew the quick connector from thehydraulic hose. (21 mm spanner).

NOTE!

There is a gasket between thepump and tank.

186

8

H

K

F

B

G F

G

C

B

D E

H

F

K

Hydraulic unit

Remove the bolt (B), and the plugs (C) and(D) to make it easier to clean the valveblock.

Remove the plug (C) and bolt (B).

Clean and inspect all components in thevalve block and assemble in the reverseorder set out for dismantling.

Check the piston (F). If it is scratched orscored it should be replaced with thevalve block.

Press in the piston using a small screw-driver when the bolt (B) is fitted.

In the event of wear or damage to thehydraulic pump this must be replaced witha new one. Assemble all components inthe reverse order set out for dismantling.

The washers (G) are special hydraulicsealing washers with a V shaped rubberring as a seal.

It is extremely important that these wash-ers seal correctly.

Control valve operationModel 235 PThrottle (H) in the idling position.

No hydraulic oil flows through the controlvalve.

Piston (F) in the rest position.

Pressure blade (K) in the open position.

Throttle (H) at full throttle.

The hydraulic oil flows through the controlvalve. In the first stage the oil is forcedthrough the overflow hole in the piston (F)which starts to move once the springpressure is counteracted.

Pressure blade (K) in the open position.

NOTE!

A piston presses against bolt (B)by means of a spring (seeillustration below). Remove theplug (D) as well to make it easierto clean the valve block.

Replace the O-ring (E).

187

8

H

K

F

H

K

F

H

K

F

502 52 16-01

Hydraulic unit

Replacing the clutchdrum and bearingModel 235PDismantle the hydraulic pump and con-trol valve.

Lock the clutch drum and loosen thepump drive screw.

Replacing the clutchdrum and bearingModel 235PDismantle the hydraulic pump and controlvalve as described above.

Lock the clutch drum using tool no.502 52 16-01 in a vice.

Loosen the pump drive screw using alarge screwdriver or suitable flat bar.

The throttle (H) in the idling position.

The piston (F) is pressed back by thespring, and the oil channel for the pres-sure blade is fully open. Oil in the hoseflows quickly back into the pump housing.

Pressure blade (K) in fully open position.

The throttle (H) is released and returns tothe idling position.

The hydraulic oil flow from the pumpceases.

The oil pressure in the hose to the pres-sure blade reduces immediately.

The oil flow returns through the hose andpasses through the overflow hole in thepiston (F).

The pressure blade (K) is pulled quicklyto the open position by the integratedspring.

Throttle (H) at full throttle.

Full hydraulic oil flow through the controlvalve.

Piston (F) is forced back completely bythe oil pressure.

The outlet channel to the pressure bladeis fully open.

The pressure blade (K) is rapidly forcedtowards its stop.

188

504 91 28-06

8 Hydraulic unit

Press out the clutch drum. Press out the clutch drum from the bear-ing using a suitable punch.

Remove the circlip and heat the pumphousing.

Remove the circlip using circlip pliers.

Heat the pump housing using a hot airgun to approx. 150°C.

Dismantle the bearing. Knock the pump housing against awooden block so the bearing falls out.

Alternatively, press out the bearing usinga punch and hammer.

Fit a new bearing.

Fit the circlip and other components.

Position the new bearing making sure itsits correctly in its seating. Use punch504 91 28-06.

Fit the circlip and other components inthe reverse order set out for dismantling.

NOTE!

Do not forget to fill with newhydraulic oil until the level isvisible in the refill hole.

Use an oil of the quality ISO VG32 at an air temperature under+20°C and ISO VG 45 at an airtemperature over +20°C.

189

502 52 30-01 502 52 28-01

8Hydraulic unit

Capacity testModel 235PThe capacity of the hydraulic pump istested as follows:

Test run the unit with the pruner attach-ment with varying loads for about 5 min-utes so the oil becomes warm.

Now fit adapter 502 52 30-01 and pres-sure gauge 502 52 28-01.

Check the oil pressure under load. Itshould be min. 90 bar (9 MPa).

If the pressure is lower, this can be due toleakage or internal pump wear. If this isthe case replace the pump.

Capacity testModel 235PTest run the unit under varying loads forabout 5 minutes so the oil becomes warm.

Connect the adapter and pressure gauge.

Check the oil pressure. It should be min.90 bar (9 MPa).

190

191

9.Attachments

ContentsHedge trimmer _________________________________ 192

Blower ________________________________________ 197

Pruning saw ___________________________________ 197

Chain sprocket and bar _________________________ 200

Hydraulic motor _______________________________ 201

Cutting equipment ______________________________ 204

192

9

A A

B

C

Attachments

liness has an even greater significance than whenservicing the engine. The smallest impurities en-tering the hydraulic system can result in down-time. Defective and leaking hoses and couplingsshould be replaced immediately with new ones.Pay special attention to the high oil pressure in ahydraulic system, which can cause personal in-jury in the event of sudden leakage from a hose orcoupling.

A brush cutter has proven to be very suitable foruse as a power source for many other applica-tions. By fitting it with different types of adaptersit’s possible to connect different types of attach-ments. These attachments are carefully testedtogether with the engine and their specificationsmust not be modified so that safety and theirservice life are not jeopardised.The same care and exactness apply to theseattachments as apply to the engine when servic-ing. For the hydraulic powered attachments clean-

Hedge trimmerModels 225 H60/H75Dismantling the gearboxSeparate the engine and the cutting equip-ment.

Hedge trimmerModels 225 H60/H75Dismantling the gearboxSeparate the engine and the cutting equip-ment as follows:

Remove the 4 bolts (A) and (B) by thevibration dampers.

Dismantle the cutting equipment from theengine.

Remove the bolts holding the clutch coveron the crankcase.

Lift off the clutch cover complete with thecutting equipment.

Remove the bolts and the grease refillplug.

Lift off the cover.

Remove the 5 socket headed bolts andthe grease filling plug (C).

Later designs have a further 2 bolts toreinforce the cover.

Lift off the cover over the gearbox.

WARNING!

The transport guard shouldalways be fitted whenworking on the cuttingequipment to avoid cuttingyour hands.

!

193

9

D

G

G

F

H

K

E

505 38 17-09

Attachments

Dismantle the bearing. Heat the gearbox to about 150°C by usinga hot air gun and dismantle the bearingusing punch no. 505 38 17-09.

Do not remove the circlip.

Dismantle the clutch drum. Remove the circlip (K) and press out theclutch drum using a punch and hammer.

Remove the blades, connecting rod andprotective plate.

Remove the seal (F) and both bolts (G)that hold the cutting equipment on thegearbox.

Remove the blades, connecting rod andprotective plate (H).

Note which way the protective plate facesso it can be reassembled in the same way.

Lift out the connecting rod and the gearwheel.

Lift out the connecting rod (D) and thegear wheel (E).

194

9

505 38 17-09

503 62 12-01

Attachments

Assembling the gearboxHeat the gearbox and fit the bearingagainst the circlip.

Assembling the gearboxHeat the gearbox to about 150°C by usinga hot air gun and position the bearing.Use punch no. 505 38 17-09 to press thebearing against the circlip.

Fit the clutch drum and the remainingcomponents in the reverse order set outfor dismantling.

Fit the clutch drum while the bearing isstill warm.

Fit the circlip and the remaining compo-nents in the reverse order set out fordismantling.

Hedge trimmerModel 18HRemove the cover over the gearbox.

Hedge trimmerModel 18HRemove the 4 screws and lift off the coverover the gearbox.

Remove the cutting equipment. Unscrew the 2 bolts and lift off the cuttingequipment.

NOTE!

Fit the gear wheel with bevellededge facing upwards.

The X punched on the connectingrods should face each other.

Tighten the bolts for the blades sothey butt against the spacer.

Do not forget to fill the gearboxwith grease.

195

9

502 50 57-01 502 52 16-01

A

A A

A

B

B

Attachments

Dismantle the clutch drum and the bolts(B).

Dismantle the clutch drum. Loosen (anti-clockwise) the axle (A) using the allen key502 50 57-01 (3/16") and possibly tool no.502 52 16-01.

Remove the bolts (B).

Dismantle the clutch housing. Unscrew the 4 bolts and lift off the gear-box.

Dismantle the steel loop and springs. Remove the 3 screws and lift off the steelloop together with the springs.

Lift off the gear. Lift off the gear.

NOTE!

Do not lose the small bearingsleeve (A).

NOTE!

The bolts (A) do not need to beremoved.

196

9

503 62 12-01

504 90 90-01

Attachments

Press out the gear with the bearing fromthe gearbox.

Use a suitable punch and hammer.

Press out the gear with the bearing fromthe gearbox.

Pull the bearing off of the clutch axle. Pull off both bearings at the same timefrom the clutch axle by using a smallpuller, e.g. no. 504 90 90-01.

AssemblyFit a new bearing on the clutch axle.Lubricate with grease.

AssemblyFit a new bearing on the clutch axle.

Fit the bearing together with the clutchaxle in the gearbox.

Press in the bearings together with theclutch axle into the gearbox by using asuitable punch and hammer. Tighten bothscrews that prevent the bearings fromsliding out of their seatings.

NOTE!

Lubricate the bearings with greaseand fit them on the axle so that thebearings’ open faces are oppositeeach other.

197

9

504 91 06-05

503 62 12-01

A

B B

Max

. 62.

5 m

m

• A

B

Attachments

Pruning sawModel 250PSDismantling

Remove the guard over the drive sprocket.

Loosen the chain adjuster screw (A) andremove the bolts (B).

Pruning sawModel 250PSDismantling

The cutting equipment consists of a chain,bar and hydraulic motor.

Remove the 2 bolts holding the guardover the drive sprocket and loosen thechain adjuster screw (A).

Remove the bolts (B).

Replace the impeller if it is damaged.Otherwise the risk of damage due to vi-bration is great.

Replace the impeller if one or more of thefan blades are damaged.

Replace the spark plug with piston stopno. 504 91 06-05.

Remove the nut (anticlockwise) and liftoff the impact blades that disintegrate thegarden waste when the vacuum device isfitted. Remove the impeller.

Assemble in the reverse order as set outfor dismantling.

BlowerModel 225HBVFold up the cover (A) if the fan and fanhousing are to be cleaned.

When replacing the impeller the fan hous-ing is split once the 11 screws have beenremoved.

BlowerModel 225HBVThe blower unit consists of a radial fanthat rotates in a fan housing.

To just clean, fold up the cover (A). Slidea screwdriver in at (B) to move the lockingspring.

If the impeller is to be replaced the 11bolts and fan housing cover must beremoved.

Check the wear on the clutch drum beforeassembling. The diameter must not ex-ceed 62.5 mm.

Check the wear on the clutch drum beforeassembling. The diameter must not ex-ceed 62.5 mm.

Fit the clutch drum on the axle and as-semble the remaining parts in the reverseorder as set out for dismantling.

Do not forget to grease the gear.

NOTE!

The sheet rail at the periphery ofthe air shell should be positionedso that the bevelled corners faceoutwards.

198

9

C

A

B

502 52 23-01

504 90 00-02

A

B

502 52 13-01

Attachments

Dismantle the chain adjuster, chain andbar.

Lift off the chain adjuster, chain and bar.

Dismantle the drive sprocket from thehydraulic motor.

Dismantle the drive sprocket from thehydraulic motor.

Hold the sprocket by using a pipe wrenchand turn the hydraulic motor’s axle clock-wise using the allen key no. 502 52 13-01.

Tip!The drive sprocket can be extremely tightand thereby difficult to hold with a pipewrench. If so, use holding tool no.502 52 23-01.

Dismantle the hydraulic motor and barmounting.

Remove the 4 bolts (A) holding the hy-draulic motor and the 4 bolts (B) holdingthe bar mounting against the ball jointbracket.

Loosen the hoses to the hydraulic motorand pull off the rubber sleeve holding thehoses together.

Loosen the hoses from the hydraulicmotor.

Pressure hose = hose coupling (A).

Return hose = hose clip (B).

Pull off the rubber sleeve holding thehoses together.

NOTE!

Do not lose the small O-ring (B)that lies behind the bar.

Exercise care so that the gasketthat lies inside the chain adjusteris not damaged.

199

9Attachments

502 42 15-01

Replace the hose guide cover if it isdamaged.

Separate the halves using a screwdriver,loosen the hose clip and pull off the cover.

The hose guide cover on the lowest han-dle tube can easily be replaced if dam-aged.

Insert a screwdriver in the cut-out in thejoint between both cover halves and twistapart.

Loosen the hose clip and pull off thecover.

If the hydraulic hose has ruptured or islikely to rupture close to a hose couplingit can be saved if cut square where rup-tured and fitted with a special repair hosecoupling.

Screw the outer, left-hand threaded sleeveof the house coupling on the hydraulichose as far as possible. Possibly lubricatewith oil and grease.

Pull apart the handle tube so that onehose at a time can be pulled through thefirst tube. Start with the return hose.

Take off the handle lock if necessary.

Now pull the hoses through the remaininghandle tubes.

Dismantle the ball joint for replacement ifnecessary by removing the screw clip orthe fluted ring nut (newer models).

NOTE!

The black outer casing must not becreased.

Now screw on the inner, right-handthreaded part of the hose coupling in theouter part.

502 40 73-02502 40 72-16

502 42 15-01

502 42 17-01502 42 16-01

200

9 Attachments

Check that the chain groove in the barand gear are in line. If this is not the casethe wear on the sprocket, chain and barwill be abnormally large and the servicelife short.

Replace the bar mounting and/or the chainsprocket to rectify the fault.

Check that the bar's guides are on thesame level. If this is not the case the sawcut will be askew and wear on the chainuneven. If so, replace the bar and chain.

AssemblyAssemble the hoses in the reverse orderas set out for dismantling.

Slide both hoses through the handle tubesimultaneously.

Assembly is simplified if the hoses arepowdered and the pressure hose is placeda little before the return hose.

Chain sprocket and barCheck that the chain sprocket rotatescentrically. If this is not the case thesprocket should be replaced with a newone.

Chain sprocket and barCheck that the chain sprocket rotatescentrically, i.e. the chain's tension is thesame during its entire rotation.

If this is not the case the chain sprocketshould be replaced with a new one.

NOTE!

When the ball-joint is fitted thelocking pin on the screw clampshould fit in the hole on the ball-joint.

201

9

A

Attachments

Hydraulic motorDismantling

Observe the greatest degree of cleanli-ness when dismantling and assemblingthe hydraulic motor. The smallest impuri-ties can cause downtime.

NOTE!To obtain the maximum motor power it isimportant that the cover and gear are inthe same position after servicing as be-fore.

1. Make a mark on the motor housingand cover.

Hydraulic motorDismantling

Observe the greatest degree of cleanli-ness when dismantling and assemblingthe hydraulic motor. The smallest impuri-ties can cause downtime.

2. Remove the screws and separate thecover from the motor housing. 2. Remove the six screws holding the

cover.

Carefully press apart the cover andmotor housing using a screwdriver.

3. Remove the gear and key.

4. Dismantle the pump axle and its bear-ing.

5. Dismantle the sealing ring.

3. Remove the gear and key.

4. Press out the axle and bearing fromthe pump housing using a brass punchor similar material that is softer thanthe axle.

5. Dismantle the sealing ring.

Blow out the oil channel (A) in the bar withcompressed air to ensure the nose wheeland chain receive sufficient lubrication.

NOTE!

Move the impeller over to thecover by means of a screwdriver.Make sure the gears keep theirrelative positions.

1. Make a mark across the joint betweenthe motor housing and cover so thatthe parts have the same relative posi-tions after servicing.

NOTE!

To obtain the maximum motorpower it is important that the coverand gear are in the same positionafter servicing as before.

202

9

A B

502 52 25-01

C

Type D

Attachments

AssemblyIn order to also use the hydraulic motortogether with an external hydraulic sys-tem, the axle seal on motors marked witha “D" on the cover have a hydraulic sealinstead of the conventional axle seal towithstand a higher return line pressurethat can be up to 40 bar in many cases.This modification was introduced into pro-duction from the middle of 1995 (see theserial number plate on the pruning saw).

1. Place the seal retainer (C) on the axlewith the flange facing the bearing.

1. Place the seal retainer on the axlewith the flange facing the bearing.

2. Slide the sealing ring (A) into position.

3. Press down the O-ring (B) correctly inthe gap between the sealing ring andthe seal retainer.

2. Lubricate the axle with a few drops ofoil and slide the sealing ring (A) care-fully over the axle's sealing surface.

3. Press down the O-ring (B) betweenthe sealing ring and the seal retainer.Use your thumb nail!

6. Dismantle the cover plate in the bot-tom of the bearing seating.

6. Remove the cover plate positioned inthe bottom of the bearing seating usingpunch no. 502 52 25-01.

Insert the punch through the axle holefrom the bearing side and place thewasher on the punch under the coverplate. Knock the punch against thebench. Move the punch around thecover plate to prevent the washer fromturning and jamming in the bearingseating when dismantled.

NOTE!

Check that the O-ring sitscorrectly in the gap between thesealing ring and retainer.

203

9

502 52 24-01

502 42 50-01

Attachments

5. Fit the axle with the bearing fitted inthe motor housing.

Check that the axle can rotate freely.

5. Press in the axle with the bearing fittedin the motor housing. Hold the housingin your hand and press in the bearingusing sleeve no. 502 52 24-01. Checkthat the axle can rotate freely.

6. Check that the O-ring is undamagedand fit the key in the axle. Place thegear and pump impeller in position inthe cover and secure it in place on themotor housing.

6. Check that the O-ring, which sealsbetween the cover and the motor hous-ing, is undamaged.Fit the key on the axle.Place the gear and impeller in posi-tion in the cover so that they come inthe same position relative to eachother as before servicing.Fit the cover on the motor housing.Rotate the axle so that the key entersthe gear.Make sure the marking on the coveraligns with the mark on the motorhousing.Tighten the screws crosswise and di-agonally.

In connection with the introduction of thehydraulic seal type “D” the relief valvemust be replaced with one that has ahigher opening pressure (40 bar).

This valve has order no. 503 83 17-01.

Use tool no. 502 42 50-01 to replace thevalve.

In connection with the introduction of thehydraulic seal type “D” the relief valvemust be replaced with one that has ahigher opening pressure.

This valve has order no. 503 83 17-01.

Use tool no. 502 42 50-01 to replace thevalve.

4. Place the cover plate, with the cham-fer facing inwards, in position on themotor housing.

4. Place the cover plate in position in themotor housing. The chamfer shouldface inwards to facilitate assembly.

NOTE!

Motors manufactured before themiddle of 1995 (no "D" markingon the cover) have a metal discplaced on the outside of thesealing ring. This disc must notbe fitted when the abovementioned seal type is used.

204

9

A

B

C

Type E

Attachments

The hydraulic motors with the designa-tion "E" punched on the cover have aslightly different seal mounting comparedwith type "D".

On these motors the hydraulic seal is thesame as on the "D" type, but is fitteddirectly in the motor housing without theseal holder (C).

The new mounting, type "E", has beenintroduced into production from serialnumber 709 50 33 on the handle.

Cutting equipmentModel 235PReplacing the pruning bladesRemove the nut, circlip and bearing pin.

Cutting equipmentModel 235PReplacing the pruning bladesRemove the nut (A) and circlip (B). Holdyour thumb over the circlip so it does notfly away.

Remove the bearing pin.

Remove the bolt and bearing sleeve andthe moving blade.

Grind or replace the blade and reassem-ble in the reverse order set out for disman-tling.

Remove the bolt (C) with its bearingsleeve.

Remove the moving blade for grinding orreplacement.

Reassemble in the reverse order set outfor dismantling.

Ensure the moving blade can move unim-peded when the pruner is squeezed to-gether by hand.

It should move to the open position underits own force.

Ensure the moving blade can move unim-peded when the pruner is squeezed to-gether by hand.

It should move to the open position underits own force.

205

E

AB

D

C

C

A

A

B

9Attachments

Loosen the screw (E) just enough so thereturn spring releases.

Make sure the hydraulic piston is fullyinserted in the cylinder.

Now loosen the screw (E) just enough sothe return spring releases.

Pull the piston out of the cylinder.

Remove the 3 bolts (C) and the bearingpin respective spiral pin (D).

Remove the cutting equipment.

Remove the 3 bolts (C) and the bearingpin respective spiral pin (D).

Remove the cutting equipment.

Replacing the seals in the hydrauliccylinder

Dismantling

Loosen the hose clip.

Pull out the hydraulic hose and loosen itby the cutting equipment.

Replacing the seals in the hydrauliccylinder

Dismantling

Loosen the hose clip (A) and pull out theentire cutting equipment so the hydraulichose connector (B) is accessible.

Unscrew the hydraulic hose.

Drain the oil from the hydraulic cylinder.

Replacing the pressure blade

Dismantle the spiral pins (A) and (B) andthe bolt (C).

Lift off the stop and blade.

Replacing the pressure blade

Dismantle the stop by removing bolt (C)and pressing out the spiral pin (B).

Dismantle the pressure blade by pressingout both spiral pins (A).

Assemble in the reverse order set out fordismantling.

NOTE!

Put a support under the cuttingequipment to avoid deformity.

206

502 52 26-01

502 52 27-01

A

B

9

F G

Attachments

Dismantle the sealing ring, slide ring andO-ring.

Carefully pry out the sealing ring (F) fromits groove using a small screwdriver andthe slide ring (G) (and the underlaying O-ring) with a pointed object.

AssemblingClean and check all components withregard to wear and damage.

Replace the piston and cylinder if theslide surfaces are scored.

Fit the O-ring in the groove.

AssemblingClean and check all components withregard to wear and damage.

Use assembly tool 502 52 27-01 to fit thenew slide ring.

Remove the spacer from the cylinder.

Fit a new slide ring.

Use assembly tool 502 52 27-01.

Place the ring loosely on the bar betweenthe punch (A) and stop (B).

Insert the punch and slide ring in thecylinder so that they come under thegroove.

Insert the punch and slide ring in thecylinder so that they come under thegroove where the previously fitted O-ringis positioned.

NOTE!

Take immense care so that thehydraulic cylinder's slide surfaceis not damaged.

NOTE!

If the piston and cylinder havescore marks on the slidesurfaces these should bereplaced by new components.

Fit the O-ring in the groove.

First slide the spacer 502 52 26-01 in thecylinder and then push the O-ring in thegroove.

207

D

C

9Attachments

Check that the screw holding the returnspring is tensioned.

Fit the cutting equipment and the hydrau-lic hose in the reverse order set out fordismantling.

Tighten the screw holding the spring onthe piston if it was loosened earlier tofacilitate assembly.

Fit the cutting equipment and the hydrau-lic hose in the reverse order set out fordismantling.

Check that the sealing washer on thehose connector is not damaged. Fit witha new if necessary.

Lubricate the piston and cylinder usinghydraulic oil.

Insert the piston and return spring in thecylinder and screw in the bolt (D) throughthe eye on the spring.

If necessary loosen the screw that holdsthe spring in position on the piston tofacilitate assembly.

Lubricate the piston and cylinder usinghydraulic oil.

Fit the piston in the cylinder and securethe spring to the bottom of the cylinderusing bolt (D).

Fit a new wiper ring and ensure that itenters the groove correctly.

Fit a new wiper ring and ensure that itenters the groove correctly.

Slide the stop (C) down towards the cylin-der and pull the ball on the tool until theslide ring snaps into position.

Slide the stop (C) down towards the cyl-inder edge.

Now pull the ball on the tool until the slidering snaps into position.

NOTE!

Check that the sealing washerunder screw (D) is in position andundamaged.

208

209

10.Tools

ContentsAngle gear/gearbox ______________________ 210

Centrifugal clutch ________________________ 211

Bearing/crankcase/vib. damper/crankshaft ____ 212

Sealing ring _____________________________ 213

Fuel system/ignition system ________________ 214

Leakage testing _________________________ 215

Hydraulic unit ___________________________ 216

Attachments ____________________________ 217

Cylinder and piston/workshop equipment _____ 218

210

10

502 51 11-01

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 51 68-01 502 50 65-01 503 97 64-01 503 62 12-01 503 80 17-01

● ● ●

● ● ●

● ● ●

● ●

●

● ●

●

●

●

●

●

●

●

●

●

List of tools

Angle gear, gearbox

Mo

del

211

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 52 17-01 502 52 15-01 502 52 16-01 505 26 79-12 502 50 49-01

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● ● ● ●

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● ●

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502 52 13-01 (4 mm)502 52 14-01 (6 mm)

List of tools

Angle gear, gearbox

Mo

del

Centrifugal clutch

212

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

18 mm

504 90 90-01 502 51 61-01 502 50 66-02 502 50 30-10 502 50 30-07

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502 50 30-08

List of toolsM

od

el

Bearings Crankcase Vibrationdamper

Crankshaft

213

10

505 38 17-09504 91 28-06502 50 30-09 504 91 40-01 502 50 53-01 504 91 28-00

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265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

List of toolsM

od

el

Sealing ringCrankshaft

214

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 50 83-01 501 60 02-02 531 00 48-63 502 51 94-01 502 71 13-01

CARB EPA

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505 26 79-12

List of tools

Ignition system

Mo

del

Fuel system

215

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 51 34-02 531 00 48-61 531 00 48-62 502 51 49-01 502 54 11-01502 50 06-01

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List of toolsM

od

el

Ignition systemLeakagetesting

216

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 50 37-01502 50 38-01 502 52 28-01 502 52 30-01

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503 84 40-01

+ –

502 42 45-01

Mo

del

List of tools

Leakage testing Hydraulic unit

217

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

502 52 26-01 502 52 27-01

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502 42 50-01 502 52 23-01502 52 24-01 502 52 25-01

Mo

del

List of tools

Cutting equipment

218

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

503 26 70-01502 50 70-01 505 38 17-05531 00 48-65

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504 91 06-05 502 54 15-01

Workshopequipment

List of tools

Cylinder/piston

Mo

del

219

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

504 90 00-02 504 90 00-03 504 90 00-01

4 mm 5 mm 6 mm

504 90 00-06

504 90 00-01–04+ 502 50 22-01

=3/16"

502 50 57-01

3 mm

504 90 00-04

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Mo

del

List of tools

Workshop equipment

220

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

M 6

502 51 67-01 502 50 88-01502 50 22-01

8 mm

502 50 23-01

10 mm

502 71 27-01

25 x 150

502 71 31-01

30 x 200

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Mo

del

List of tools

Workshop equipment

221

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

505 69 85-70502 02 61-02 502 71 14-01 502 51 03-01

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M 5

502 50 87-01

M 4

502 50 86-01

Mo

del

List of tools

Workshop equipment

Degreasing agent

222

10

265

252

250

240/245

225/232/235

240RBD

122

32

Mondo Mega

Mondo

Mondo Max

250PS

235P

225 H60/H75

18H

322

325

140B/141B

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Size S: 101 64 23-48M: 101 64 23-50L: 101 64 23-52

XL: 101 64 23-54XXL: 101 64 23-56502 51 54-01 502 21 58-01

Mo

del

List of tools

Workshop equipment