Husqvarna K 960 Instruction manual

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K 960

1. LITERATURE 2

2. SPECIAL FUNCTIONAL COMPONENTS 3

3. COMPONENTS – ORIENTATION 4

4. DISMANTLING INTO BASIC MODULES 5

5. STARTER 9

6. IGNITION SYSTEM 12

7. FLYWHEEL 15

8. AIR FILTER 17

9. INLET SYSTEM 18

10. FUEL SYSTEM 20

11. CARBURETTOR 23

12. DECOMPRESSION VALVE 28

13. CYLINDER/PISTON 29

14. CRANKCASE 35

15. CLUTCH 40

16. CUTTING HEAD 44

17. FRICTION RETARDER 49

18. HANDLE 51

19. TOOLS 52

CONTENTS Page

HUSQVARNA

K 960

502 53 07-26

LITERATURE1

Workshop Manual

The Workshop Manual includes virtually

all workshop procedures that can come into

question on the K960. Some very simple and

self-evident repairs have been omitted.

Outline

An introductory section with the title

“Dismantling into Basic Modules” shows how

the machine is dismantled into large component

units, for example, the starter, cutting arm, air

filter, etc.

The manual goes on to describes in detail

through the different chapter how work on the

basic modules should be carried out.

This arrangement means that as a mechanic,

at least until you have learnt the basic composi-

tion of the machine, you need to start with the

chapter “Dismantling into Basic Modules” to

then move on to the chapter covering the speci-

fic service work.

Layout – pictures and text

Besides the pictures and illustrations there is

generally two columns of text. The left-hand text

column is a concise and is suitable for experienced

mechanics, the right-hand column gives a more

detailed description and is targeted at mechanics

with less experience of repair work on the power

cutter.

Contents

The manual is divided into numbered chapters

together with chapter headings that are stated in

bold at the top of each page.

The list of contents also has page references to

the start of each chapter.

Spare parts

Spare parts K960

The folder includes all the spare parts for

Husqvarna K960.

The folder contains complete exploded views

of the entire machine where each component's

placement, spare part number and appearance

can be easily identified.

HUSQVARNA CONSTRUCTION PRODUCTS

Workshop manual

K 960

“Dismantling into Basic Modules”

“Cutting head” (Example)

502 53 07-26

SPECIAL FUNCTIONAL COMPONENTS

New technical solutions

Husqvarna K960 is the first model in a new

generation of power cutters with a number of

new technical solutions:

New engine technology – Dual

Charge

The cylinder, piston and carburettor are

radically changed.

The carburettor's inlet duct (venturi) is

split in two halves. The upper venturi half (A)

supplies the cylinder with clean air while the

lower half (B) gives an over-rich fuel/air mix-

ture. By leading the fuel-air mixture and the

clean air in separate flushing channels into

the cylinder, the proportions of the air-fuel

mixture and clean air can be controlled so

that these vary in different phases of the

engine's work cycle.

Cleaner exhaust fumes and improved

performance

The amount of uncombusted hydrocarbons

(HC) is reduced by the Dual Charge techno-

logy to about half compared with a tradi-

tional design. The emission values are now

well below levels in the regulations from

EPAII.

The output is higher over the entire speed

range and the torque in the lower speed range

is now significantly higher.

Lower vibration levels

The fuel tank is integrated in the handle unit,

which means lower handle vibrations through

the greater weight. A redesigned vibration

dampening element gives lower vibration

levels, compared to the forerunner K950.

Poly-V belt

This type of belt has improved strength and

is more resilient against stretching than pre-

vious V-belts, which results in longer intervals

between adjustments. Friction losses are also

less.

Friction Retarder

A new front belt pulley is being introduced in

2007 with a braking mechanism that takes

effect at low speeds.

Torx – T27

Torx screws, with the dimensions T27, are

used virtually throughout to simplify the ser-

vice work.

Note that screws with both a flat and fluted

undersides are used.

Torx T27

COMPONENTS – ORIENTATION3

Components

1. Cutting blade

2. Blade guard

3. Adjustable handle for the blade guard

4. Front handle

5. Air filter cover

6. Cylinder cover

7. Fuel tank

8. Starter handle

9. Starter

1314

10. Combination spanner

11. Belt adjustment screw

12. Lock screws for belt adjustment

13. Cutting arm/rear belt guard

14. Throttle control

15. Rear handle

16. Throttle trigger lock

17. Water valve with tool attachment

18. Water connector

19. Choke Lever

20. Start throttle lock

21. Stop switch

Basic modules

This chapter shows how the machine is

built up of basic modules, for example,

the starter, carburettor, air filter system,

etc.

The purpose is to illustrate how you

can easily and effectively dismantle and

assemble the machine in its basic modules.

Service work on a component level, for

example, replacing the starter cord, is

described in detail in respective chapters.

Cutting head

1. Loosen the screws on the cutting head.

2. Slacken off the belt tension using the

adjuster screw. Dismantle the screws on

the cutting head.

3. Dismantle the front belt cover by

sliding it forwards.

4. Loosen the hoses by the water valve.

Lift off the belt from the pulley and

remove the cutting head.

5. Loosen the two screws on the rear belt

guard.

(Tightening torque when assembling

6.6–8.1 lbf·ft/9–11 Nm.)

6. Remove the guard.

DISMANTLING INTO BASIC MODULES 4

Starter

1. Loosen the 4 screws on the guard.

2. Dismantle the starter.

DISMANTLING INTO BASIC MODULES

Air filter

1. Loosen both screws on the guard and

remove the guard.

2. Lift off the filter base.

3. Carefully lift up the paper filter so

that dust does not fall down into the

inlet bend.

Cylinder cover

1. Loosen the three screws on the

cylinder cover.

2. Lift off the cylinder cover.

Carburettor

1a. Dismantle the choke control by

turning it to the side and removing it

from its bracket.

1b. Removed the throttle rod from the

throttle and dismantle from the carbu-

rettor.

1c. Pull off the fuel hose from the carbu-

rettor.

2. Remove the first screw holding the

carburettor on the crankcase.

3. Now insert the Torx key through the

hole in the handle and loosen both

screws holding the carburettor on the

inlet manifold.

4. Remove the screws at least 10 mm.

Pull the carburettor slightly backwards, it

can now be lifted upwards.

5. Remove the guide for the carburettor

setting from the machine.

DISMANTLING INTO BASIC MODULES 4

Air duct

Dismantle the entire air filter unit,

cylinder cover and starter.

Note how the cable to the stop switch

and the ignition lead are fitted in the air

duct.

Loosen the ignition lead from the

spark plug and release the cable from the

air duct.

Loosen the cable lug on the ignition

module and the stop switch. Remove the

air duct.

Inlet nozzle

There are two flywheel positions where

the screws become accessible. Dismantle

the screw and pull out the nozzle.

Inlet manifold

Dismantle the entire air filter unit,

cylinder cover, starter, air duct and car-

burettor.

The cylinder must be lifted slightly to

replace the inlet manifold between the

carburettor and cylinder. See the detailed

description on page 21.

Assembly

6. Pre-assemble the components as

illustrated. Slide the screws slightly past

the contact face.

7. Note the partition wall in the inlet

manifold. Note that the marking “UP”

must face upwards, if the partition wall

was loosened when dismantling the car-

burettor.

Muffler

Dismantle the cutting head, air filter and

cylinder cover.

The muffler is secured by three screws.

Dismantle these and remove the muffler.

Assembly

The insulated fibre gasket should lie

against the muffler.

The heat shield should lie closest to the

cylinder.

M5 M5

DISMANTLING INTO BASIC MODULES4

Vibration dampening

Several service procedures can be facilitated by splitting the machine at the

vibration dampening element. Perform the following before splitting:

– dismantle the air filter unit and cylinder cover

– dismantle the starter

– loosen the cable lug on the ignition module and the stop button and

remove the air duct

– pull off the water hose by the valve

– pull off the fuel hose from the carburettor

– dismantle the throttle rod and choke control.

The engine unit is attached to the handle unit at four points with the

vibration dampening element in the form of springs.

To gain access to the spring's inner screw, the diameter of the Torx key

must be max. 5 mm. The combination spanner fits.

Individual vibration dampers can be replaced on a complete machine as

described below in the section “Actions for replacing”.

Splitting the machine

Dismantle the outer screws on the vibra-

tion dampers:

1. Behind the machine's ground support

Actions for replacing: The machine must

be split as described above. Dismantle

the muffler too.

2. Below the flywheel

Actions for replacing: Dismantle the star-

ter.

3. The handle loop by the cylinder

Dismantle the inner screw in the cylinder.

Actions for replacing: Dismantle the

vibration damper first.

Open the snap lock on the hose holder

and push out the hose (the lowermost

picture). Assemble in the reverse order.

4. Below the carburettor space

Actions for replacing: Dismantle the

starter, filter and cylinder cover. Dis-

mantle the throttle rod and pull the fuel

hose from the carburettor. Dismantle the

outer screws for the vibration dampers

according to 2 and 3.

Lift up the engine body at the rear and

dismantle the vibration damper.

Coarse thread

MT6

1 2

3 4

STARTER 5

Replacing the starter cord

Dismantle the starter.

Eliminate the spring force from

the return spring

1. Pull out the starter cord approximately

12 in./30 cm. Hold the starter pulley

with your thumb and place the cord in

the cut-out on the starter pulley.

2. Let the starter pulley rotate slowly and

wind up the cord on the metal sleeve.

3. Lift off the cord from the starter

pulley.

Attach the new starter cord

The starter cord should be 45 in./

115 cm long and have a diameter of

.16 in./4 mm.

1. Insert one end of the cord from the

top through the hole in the starter pulley

and then out through the notch for the

cord. Pull out virtually the whole cord

length until sufficient cord remains to tie

a knot as illustrated.

2. Insert the other end through the cover

and on through the handle. Tie a double

knot as illustrated.

Loading the return spring

1. Fit the starter cord in the cut-out.

2. Wind the starter cord 4 turns around

the hub.

3. Pull out the starter handle so the cord

rolls off the hub.

4. Release so the cord is wound on the

starter pulley.

Repeat the procedure with 3 turns of

cord around the hub.

Important check!

Check that the return spring does not act

as an end stop by extending the cord

fully. In this position it should be possible

to turn the starter pulley a least a further

half turn before the spring stops the

movement.

1 2

3 4

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