Husqvarna 61 Chainsaw Workshop Manual

The Husqvarna 61 is a professional-grade chainsaw featuring a 61cc engine, automatic oiling system, inertia-activated chain brake, anti-vibration system, and side-mounted chain tensioner. This workshop manual provides detailed instructions for maintenance, repair, troubleshooting, and safety procedures. Below are key sections covering specifications, safety, disassembly, engine service, fuel system, ignition, lubrication, guide bar & chain, assembly, and troubleshooting.

Specifications & Identification

Key identification: Model 61, serial number located on crankcase. Engine type: 2-stroke, single cylinder.

Safety Precautions

Always disconnect spark plug before servicing. Wear protective gloves and eyewear.

1. Fuel Safety: Work in well-ventilated area; no smoking or open flames.
2. Chain Safety: Ensure chain brake is engaged; handle chain with cut-resistant gloves.
3. Pressure & Vacuum Testing: Use appropriate adapters; do not exceed specified pressures.
4. Springs & Clips: Use retaining tool; springs under tension can cause injury.

WARNING! Fuel and oil are flammable. Avoid skin contact with fuel mixture. Chain is extremely sharp.

Tools & Workshop Requirements

Special tools: Flywheel puller (Husqvarna 502 50 86-01), piston stop, clutch tool, compression tester, pressure/vacuum pump.

1. Standard Tools: Torx T27, socket set (8-13mm), feeler gauges, torque wrench.
2. Cleaning: Parts washer, carburetor cleaner, compressed air.
3. Workspace: Clean, well-lit bench with vise (use soft jaws).
4. Consumables: Gasket set, fuel line, impulse line, diaphragm kits, bar oil.

CAUTION! Use correct tools to avoid damage to components.

Disassembly Sequence

• Step 1: Remove top cover, air filter cover, and air filter.
• Step 2: Remove spark plug, disconnect fuel line, drain tanks.
• Step 3: Remove clutch (left-hand thread), guide bar, chain, sprocket.
• Step 4: Remove carburetor, intake manifold, and cylinder cover.
• Step 5: Remove muffler, cylinder bolts, cylinder.
• Step 6: Remove piston pin circlips, pin, piston.
• Step 7: Remove flywheel (pull required), ignition module.
• Step 8: Separate crankcase halves after removing all screws.

Engine Service

Cylinder & Piston: Inspect for scoring, measure wear. Piston rings: Check end gap (0.3-0.5mm). Crankshaft: Check runout (max 0.05mm), bearing play. Crankcase: Check for cracks, seal surfaces.

Compression Test: Should be 120-150 psi (new). Below 100 psi indicates wear.

Crankcase Pressure/Vacuum Test: Apply 0.5 bar pressure; should hold for 30 seconds. Leaks indicate bad seals or gaskets.

Fuel System

Carburetor (Walbro HDA): Disassemble, clean jets, check diaphragms and gaskets. Needle valve: Check for wear. Adjustment screws: Initial settings L: 1 turn out, H: 1 turn out. Fine-tune for smooth acceleration.

1. Fuel Filter: Replace if clogged.
2. Fuel Lines: Check for cracks, replace if hardened.
3. Impulse Line: Connects crankcase to carburetor; must be airtight.
4. Tank Vent: Ensure it is clear.

Tip: Use ethanol-free fuel mix (50:1 Husqvarna XP oil) to prevent carburetor issues.

Ignition System

Spark Plug: Gap 0.5mm. Ignition Module (SEM): Check air gap (0.3mm) to flywheel. Resistance check: Primary coil 0.2-0.3 ohms, secondary 8-12 kOhms. Flywheel: Check magnets, keyway.

No Spark: Check kill switch wire for short to ground, module grounding, flywheel key sheared.

Lubrication System

Automatic Oiler: Pump driven by worm gear on clutch drum. Check oil passages, filter screen in tank. Manual override (if equipped): Check plunger operation.

1. Remove oil pump: Clean pickup filter.
2. Check adjustment screw: Controls oil flow rate.
3. Test: Run saw at high RPM with bar tip near cardboard; should throw oil line.

WARNING! Never run saw without bar oil; causes rapid chain and bar wear.

Guide Bar & Chain

Bar: Inspect for straightness, groove wear, sprocket tip condition. Dress rails with flat file if burred. Chain: Sharpen with round file (size per chain). Check depth gauges (raker height 0.025" below cutter).

Sprocket: Replace if worn (clutch drum sprocket).

Chain Tension: Adjust so chain snaps back when pulled from bar.

Reassembly & Adjustment

Assembly is reverse of disassembly with attention to torque values and sealant.

Final Adjustments: Carburetor tuning, chain tension, idle speed (2800-3200 RPM), chain brake function test.

Troubleshooting

Service Intervals: Air filter daily, spark plug every 25 hours, fuel filter every 100 hours.

Parts & Support: Genuine Husqvarna parts recommended. Contact authorized dealer or Husqvarna customer service.