Husqvarna 61 Chainsaw Repair Manual

The Husqvarna 61 is a professional-grade chainsaw known for its reliability and power. This repair manual provides comprehensive instructions for maintenance, troubleshooting, and repair of the Husqvarna 61 chainsaw, including the engine, ignition system, fuel system, chain brake, clutch, guide bar, and cutting chain. Below are key sections for safety, specifications, disassembly, repair procedures, and troubleshooting.

1. Safety Precautions 2. Specifications 3. Tools Required 4. Engine System 5. Fuel System 6. Ignition System 7. Chain & Bar Assembly 8. Clutch & Sprocket 9. Chain Brake System 10. Troubleshooting Guide 11. Parts List & Diagrams

Safety Precautions

Always prioritize safety when performing repairs. Wear appropriate personal protective equipment (PPE).

Precaution	Description
Disconnect Spark Plug	Always disconnect the spark plug wire before starting any repair to prevent accidental starting.
Use Proper Tools	Use tools designed for chainsaw repair to avoid damage and injury.
Work in Well-Ventilated Area	Perform repairs in a clean, well-lit area away from flammable materials.
Handle Fuel Safely	Drain fuel tank before working on fuel system; no smoking or open flames nearby.
Wear Gloves & Eye Protection	Protect hands from sharp edges and eyes from debris.
Secure Chainsaw	Clamp or secure the chainsaw firmly before disassembly.
Follow Torque Specifications	Use a torque wrench for critical fasteners to prevent over-tightening.
Dispose of Fluids Properly	Dispose of old oil, fuel, and coolant according to local regulations.
Inspect Chain Brake	Test chain brake function after reassembly.
Check for Leaks	Inspect for fuel and oil leaks after repair.

Specifications

Model: Husqvarna 61
Engine Type: 2-stroke, single cylinder
Displacement: 61 cc (3.7 cu in)
Power Output: Approximately 3.7 kW (5.0 hp)
Fuel Tank Capacity: 0.85 L (0.22 US gal)
Oil Tank Capacity: 0.35 L (0.09 US gal)
Guide Bar Length: Typically 15-24 inches (38-61 cm)
Chain Pitch: 3/8 inch or .325 inch
Ignition System: Electronic (SEM or Bosch)
Weight (without bar & chain): Approximately 6.2 kg (13.7 lbs)
Spark Plug: Champion RCJ7Y or equivalent, gap 0.5 mm (0.020 in)

Tools Required

Basic and specialized tools needed for repair.

Socket set (metric: 8, 10, 13 mm)
Screwdrivers (flathead and Phillips)
Torx drivers (T27 for clutch)
Feeler gauge set
Compression tester
Spark tester
Chain breaker and spinner
Clutch removal tool
Piston stop tool
Torque wrench (5-50 Nm range)

WARNING! Using incorrect tools can damage components and cause injury.

Engine System

Procedures for cylinder, piston, crankshaft, and bearings.

Compression Test: Attach tester to spark plug hole; pull starter. Minimum 110 psi.
Cylinder Inspection: Remove muffler; inspect cylinder walls for scoring.
Piston Removal: Remove cylinder head; use piston stop to hold crankshaft; remove circlips and piston pin.
Crankshaft Seals: Replace if leaking (common cause of air leaks).
Bearings: Check for play or roughness; replace if defective.
Reassembly: Lubricate piston rings; align arrow on piston toward exhaust port.

CAUTION! Label parts during disassembly. Clean all components before reassembly.

Fuel System

Carburetor, fuel lines, filter, and tank.

Component	Procedure
Carburetor (Walbro or Zama)	Disassemble; clean jets and passages with compressed air; replace diaphragm and gaskets.
Fuel Filter	Replace if clogged; located inside fuel tank.
Fuel Lines	Inspect for cracks; replace if hardened or leaking.
Fuel Tank Vent	Clean vent hole to prevent vacuum lock.
Adjustment Screws (L, H, T)	Initial settings: L=1 turn out, H=1 turn out, T=1-1.5 turns out. Fine-tune for optimal performance.

Tip: Use fresh fuel mix (50:1 with high-quality 2-stroke oil).

Ignition System

Spark plug, coil, flywheel, and stop switch.

Check spark plug: Clean or replace if fouled; set gap to 0.5 mm.
Test spark: Remove plug, ground to cylinder, pull starter. Strong blue spark required.
Ignition coil: Check resistance (primary: 0.5-2 Ω, secondary: 5-15 kΩ). Replace if out of spec.
Flywheel: Inspect for damage; check key for shearing.
Stop switch: Test continuity; replace if faulty.
Air gap: Set coil air gap to 0.2-0.3 mm using feeler gauge.

WARNING! High voltage present. Handle ignition components carefully.

Chain & Bar Assembly

Maintenance and replacement of cutting chain and guide bar.

Chain Sharpening: Use round file matching chain pitch; maintain 30° cutting angle.
Bar Inspection: Check for wear, especially groove and rails; dress with flat file if needed.
Chain Tension: Adjust so chain snaps back when pulled from bar.
Sprocket Nose Bar: Lubricate sprocket bearing regularly.
Chain Replacement: Match pitch, gauge, and drive link count to bar.

CAUTION! Always wear cut-resistant gloves when handling chain.

Clutch & Sprocket

Clutch assembly, drum, and rim sprocket.

Remove clutch: Use clutch tool to hold; turn clockwise (left-hand thread).
Inspect clutch shoes: Replace if worn or damaged.
Sprocket: Check for wear; replace if teeth are hooked.
Bearing: Inspect clutch drum bearing; replace if rough.
Reassembly: Torque clutch to 40-50 Nm.

Tip: Apply anti-seize compound to crankshaft threads.

Chain Brake System

Inertia-activated brake band and handle.

Component	Test/Procedure
Brake Band	Inspect for wear or cracks; replace if thickness < 0.5 mm.
Activation	With saw off, push handle forward; band should engage fully.
Spring	Check tension spring for fatigue.
Handle Mechanism	Lubricate pivot points; ensure smooth operation.
Function Test	After repair, start saw and trigger brake by hand (with chain clear).

WARNING! Never operate saw with defective chain brake.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel issue, flooded	Check spark, clean carburetor, dry plug.
Engine starts then dies	Fuel filter clogged, tank vent blocked	Replace filter, clean vent.
Loss of power	Clogged air filter, exhaust screen blocked	Clean/replace filter, remove muffler screen.
Chain won't turn	Clutch worn, sprocket damaged, brake engaged	Inspect clutch/sprocket, disengage brake.
Excessive vibration	Loose components, unbalanced flywheel	Tighten mounts, inspect flywheel.
Oil not feeding to bar	Clogged oil passages, pump defective	Clean passages, test pump output.
Overheating	Lean fuel mix, clogged cooling fins	Adjust carburetor, clean fins.
Chain throws off bar	Bar worn, chain stretched, incorrect tension	Replace bar/chain, adjust tension.

Reset: After carburetor adjustment, allow engine to warm up before final tuning.

Parts List & Diagrams

Refer to official Husqvarna parts diagrams for part numbers. Common replacement parts:

Piston Kit (Part #: 501 87 41-01)
Cylinder Kit (Part #: 501 87 42-01)
Carburetor Repair Kit (Part #: 530 03 61-02)
Ignition Coil (Part #: 544 18 40-02)
Clutch Assembly (Part #: 501 87 44-01)
Chain Brake Band (Part #: 501 87 45-01)
Fuel Line (Part #: 537 23 40-01)
Air Filter (Part #: 503 85 96-01)

Service: For genuine parts and technical support, contact Husqvarna authorized dealers or visit www.husqvarna.com.