Husqvarna 525HE3 Workshop Manual
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Husqvarna 525HE3 Workshop Manual

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Workshop manual
525HE3, 525HE4
English
1371 - 001 - 02.07.2020

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Summary of Contents for Husqvarna 525HE3

  • Page 1 Workshop manual 525HE3, 525HE4 English 1371 - 001 - 02.07.2020...

  • Page 2: Table Of Contents

    Contents 1 Introduction 1.1 Document description..........3 1.2 Target group............3 1.3 Revisions..............3 1.4 Safety..............3 1.5 Servicing tools............3 2 Safety 2.1 Safety definitions............4 2.2 General safety instructions........4 2.3 Special safety instructions........4 2.4 Symbols on the product......... 4 3 Prepare and do servicing on the product 3.1 Maintenance schedule...........

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 1371 - 001 - 02.07.2020 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions Use a protective helmet in locations where objects can fall on you. Use approved Warnings, cautions and notes are used to point out hearing protection. Use approved eye specially important parts of the manual. protection. WARNING: Used if there is a risk of injury or death for the operator or bystanders if the instructions in the manual are not obeyed.
  • Page 5 This product applies with the applicable Noise emissions to the environment EC Directives. according to European Directive 2000/14/EC and New South Wales legislation “Protection of the Environment Operations (Noise Control) Regulation 2017”. Noise emission data can be found on the machine label and in the Technical data chapter.

  • Page 6: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule Maintenance Daily Weekly Monthly Clean the external surface. After each operation. Clean the muffler, exhaust pipe and engine from leaves, dirt and unwanted lubri- After each operation. cant. Make sure that the cutting unit does not move at idle speed. Do a check of the stop switch.

  • Page 7: Servicing Data

    4 Servicing data 4.1 Servicing data ● Lubricate with grease. ▲ Lubricate with chain oil. 1.6 - 2.5 Nm 1.6 - 2.5 Nm 2 - 3 Nm 3 - 4 Nm 15 - 20 Nm 6 - 8 Nm 6 - 8 Nm 4 - 5 Nm 7 Nm 3 - 4 Nm...
  • Page 8 2.5 - 4.5 Nm 6 - 7 Nm 7 Nm 0.5 - 1.5 Nm 2 - 2.5 Nm 2 - 3 Nm 4 - 6 Nm 7 - 8 Nm 2 - 2.5 Nm 5 - 6 Nm 6 - 8 Nm 8 - Servicing data 1371 - 001 - 02.07.2020...
  • Page 9 6 - 8 Nm 6 - 9 Nm 1371 - 001 - 02.07.2020 Servicing data - 9...
  • Page 10 1.5 - 2.5 Nm 3 - 4 Nm 10 - Servicing data 1371 - 001 - 02.07.2020...

  • Page 11: Servicing Tools

    5 Servicing tools 5.1 Servicing tools 0. 3 1371 - 001 - 02.07.2020 Servicing tools - 11...
  • Page 12 Item Description Use to Article number Piston stop Lock the piston 522 43 18-01 Carburetor adjustment tool Adjust the carburetor 597 10 85-01 Torx T27 Remove and attach torx screws 502 71 27-03 Piston assembly kit Assemble the piston 502 50 70-01 Starter pawl puller Remove the starter pawl assembly 581 96 55-01...

  • Page 13: Repair Instructions

    6 Repair instructions 6.1 Product overview for repair instructions 1371 - 001 - 02.07.2020 Repair instructions - 13...

  • Page 14: To Clean And Examine The Product Parts

    1. Starter housing 3. Remove the 2 screws (D) and the muffler cover (E). 2. Muffler 3. Flywheel 4. Ignition module 5. Clutch assembly 6. Fuel tank 7. Carburetor 8. Clutch cover 9. Cylinder cover 10. Air filter cover 11. Bumper 12.
  • Page 15 3. Install in the opposite sequence. 6.4.4 To disassemble and assemble the starter unit 1. Remove the inner cover in the starter housing. Use 6.4.2 To install the recoil spring in the starter pulley a flat screwdriver. WARNING: Use protective glasses. The recoil spring can eject and cause injury.
  • Page 16 4. Lubricate the spindle with Husqvarna grease and 6. Adjust the tension of the return spring. Pull the install the starter pulley. Tighten the screw. starter rope out fully and slow the starter pulley with Assemble a new starter rope. Move it into the starter your thumb.

  • Page 17: Muffler

    b) Remove the snap ring that holds the starter 3. Remove the screw (D). pawl. Remove the starter pawls and springs. 4. Push the spark arrester (E) to the side to remove it from the muffler. 5. Install in the opposite sequence. 6.5.2 To clean and examine the muffler 1.

  • Page 18: Carburetor

    4. Put the foam air filter in a plastic bag and put 1 tablespoon of air filter oil into the plastic bag. Servicing Note: Use Husqvarna air filter oil. Refer to tools on page 11 . 5. Rub the plastic bag to supply the oil equally across 3.
  • Page 19 6.7.3 Overview of the carburetor 13 14 1. Screw 3. Spring 2. Fuel pump cover 4. Idle speed adjustment screw 1371 - 001 - 02.07.2020 Repair instructions - 19...
  • Page 20 5. Fuel pump gasket 6.7.4 To disassemble and assemble the carburetor 6. Fuel pump diaphragm Clean all parts and examine them for wear and damage. 7. Fuel screen Replace worn or damaged parts. 8. Screw To remove and 1. Remove the carburetor. Refer to 9.
  • Page 21 5. Remove the 4 screws (F). 10. Remove the screw (O) and the throttle valve plate (P). 11. Remove the screw (Q) and the throttle lever (R). 12. Remove the E-clip (S) and the throttle shaft assembly (T) together with the throttle return spring (U).
  • Page 22 6.7.5 To adjust the carburetor To adjust the carburetor means that you adjust the engine to the local conditions such as weather, altitude Basic factory settings and fuel. 525HE3, 525HE4 The carburetor has 3 adjustment controls. H = high speed jet 2.2 turns •...

  • Page 23: Shaft

    6.9 Clutch and clutch drum 4. Lower the carburetor in a container with gasoline to find leaks. 6.9.1 To disassemble and assemble the clutch 5. Make sure that there are no leaks. drum and the clutch housing 6.7.7 To remove and install the heat insulator 1.
  • Page 24 5. Remove the clamp units (B) and the rubber bushing CAUTION: Only hit with the mandrel in the (C). center of the clutch drum when you install the clutch drum. 8. Apply heat to the clutch housing until it is approximately 110°C.

  • Page 25: Flywheel

    5. Remove the clutch assembly (A) and the adapter 5. Put the piston stop in the spark plug hole. Remove (B). the nut (A) that holds the flywheel. 6. Install in the opposite sequence. 6. Remove the flywheel from the crankcase with a Servicing tools on flywheel removal tool.

  • Page 26: Ignition System

    6.10.2 To install the flywheel 6.11.2 To examine the spark plug Servicing data on page 1. Tighten the nut (A), refer to CAUTION: Always use the recommended spark 7 . Put the piston stop in the spark plug hole and put plug type.
  • Page 27 5. If no spark occurs, remove the spark plug and 5. Connect a multimeter between point (A) and point connect the ignition tester (A) to the spark plug cap (B) and measure the resistance. The measured Servicing tools on page 11 . (B).

  • Page 28: Cylinder And Piston

    To do a spark test on page 10. Do a spark test. Refer to 6. Install in the opposite sequence. Make sure that the 26 . If there is no spark, the ignition module is To install the flywheel on air gap is correct.
  • Page 29 9. Remove the 4 screws (C) and carefully remove the 11. Use the removal tool for the piston pin and remove Servicing tools on page 11 . cylinder head (D) and the cylinder head gasket (E) the piston. Refer to from the crankcase (F).

  • Page 30: Crankshaft And Crankcase

    • Put the piston ring in the cylinder and measure the space with an air gap tool. The space must not be more than 1 mm. 6.12.2 To examine the piston • Make sure that the piston ring can move freely in the groove.
  • Page 31 To remove and install 5. Remove the muffler. Refer to 13. Apply heat to the crankcase halves until they are the muffler on page 17 . approximately 110 °C. Tap the crankcase halves against a wooden block to remove the crankshaft 6.
  • Page 32 6.13.2 To clean and examine the crankshaft and WARNING: Use protective gloves. crankcase The crankshaft cannot be repaired, replace it if it is worn 2. Use a hammer and a mandrel to install the bearings or damaged. in the crankcase halves. 1.

  • Page 33: Fuel Tank

    5. Lubricate the crankshaft axle with oil and install the 8. Assemble the cylinder and piston. Refer to disassemble and assemble the cylinder and piston crankshaft assembly in the rear crankcase half. on page 28 . To install the flywheel 9.
  • Page 34 4. Increase the negative pressure in the tank. If the 6. Make sure that the snap ring (C) is attached negative pressure holds, replace the tank venting correctly. mechanism. 7. Put the fuel filter and fuel hose into the fuel tank. 6.14.2 To clean and examine the fuel filter 6.14.3 To remove and install the fuel tank 1.

  • Page 35: Handle And Throttle Trigger

    6.15 Handle and throttle trigger 6.15.1 Product overview of the throttle handle 1. Throttle trigger 6.15.2 To adjust the start throttle speed 2. Throttle lever WARNING: Use protective glasses and make 3. Recoil spring sure that the cutting attachment can rotate 4.
  • Page 36 4. Release the throttle trigger and make sure that it is 6.15.4 To disassemble and assemble the throttle locked in the start throttle position. handle 1. Remove the 5 screws and carefully remove the right 5. Start the product. handle half from the left handle half. 6.

  • Page 37: Bevel Gear

    7. Examine the vibration damping units for wear and 3. Remove the screw (C). damage. Replace the vibration damping units if it is necessary. 8. Assemble in the opposite sequence. 6.16 Bevel gear 4. Lift the handle and turn it counterclockwise. 6.16.1 To remove and install the bevel gear 5.

  • Page 38: Gearbox

    6. Hit the bevel gear carefully against a wooden block. 4. Push the locking pin with a screwdriver to release The pinion gear with the 2 bearings (B) will come the pinion gear. loose. 7. Remove the spacer ring (C), the washers (D) and the pinion gear (E).

  • Page 39: Cutting Unit

    CAUTION: Install the connection rods with the text in the direction of the gear wheel. CAUTION: Replaced or cleaned parts must be lubricated on all sides. Use Husqvarna Servicing tools bevel gear grease. Refer to on page 11 and Servicing data on page 7 .

  • Page 40: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Starting The engine is hard to start The stop screw for the throttle does not operate correctly Blocked fuel filter Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel The needle valve is defective The lever arm of the needle valve is damaged The lever arm of the needle valve does not operate correctly The control diaphragm is damaged The control diaphragm has a defective seal...
  • Page 41 Idle speed (low speed) The idle speed does not become The stop screw for the throttle does not operate correctly stable Blocked fuel filter Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel The needle valve is defective The carburetor is not attached correctly The lever arm of the needle valve does not operate correctly The needle valve spring is not attached correctly The control diaphragm is damaged...
  • Page 42 High speed Unsatisfactory performance at Blocked fuel filter high speed Blocked fuel hose Air in fuel pipes Incorrect/unsatisfactory fuel Vacuum pulse leakage Blocked vacuum pulse pipe Loose screws on the pump cover Defective pump diaphragm The needle valve is defective The carburetor is not attached correctly The lever arm of the needle valve is damaged The lever arm of the needle valve does not operate correctly...
  • Page 43 Increasing and decreasing speed Can not increase speed Defective heat insulation seal 1371 - 001 - 02.07.2020 Troubleshooting - 43...

  • Page 44: Technical Data

    8 Technical data 8.1 Technical data 525HE3 525HE4 Engine Cylinder displacement, cm 25.4 25.4 Idle speed, rpm 2800-3200 2800-3200 Recommended max speed, rpm 11000-12000 11000-12000 Maximum engine power acc. to ISO 8893, kW/hp @ rpm 1.0/1.3@8500 1.0/1.3@8500 Catalytic converter muffler...
  • Page 45 1371 - 001 - 02.07.2020 Technical data - 45...
  • Page 46 46 - Technical data 1371 - 001 - 02.07.2020...
  • Page 47 1371 - 001 - 02.07.2020 Technical data - 47...
  • Page 48 1141225-26 2020-07-02...

This manual is also suitable for:

525he4

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