Bernina 801Sport / 802 / 803 Sewing Machine Service & Repair Manual (P/N 87/1GB 390 302 030)

• Covers the 1980s–1990s Bernina 801Sport, 802, and 803 sewing machine series, including specialized S-variant trim levels.
• Official Fritz Gegauf Ltd. publication (form 87/1GB 390 302 030), originating from the Bernina factory in Steckborn, Switzerland.
• Contains 46 pages of illustrated instructions, featuring 15+ specialized sewing application charts and extensive buttonhole setup sequences.
• This 1980s first edition provides the primary factory-authorized operational parameters for the 801, 802, and 803 series units.
• Details advanced stitch configurations, including vari-overlock seams, stretch stitching, blind hemming, gimp cord buttonholes, freehand darning, multi-color appliqué, and flat joining seams.
• Outlines routine diagnostics and maintenance, covering hook race cleaning, upper thread breaks, tension errors, slow motor performance, faulty stitch prevention, and fabric-to-needle pairing.

Setup and Operation

The Bernina 801Sport, 802, and 803 PDF guide details essential machine configuration and handling. Sections break down the initial setup, including foot control connection, electrical system basics, and bobbin installation. The text clearly outlines the threading pathways for the upper thread and techniques for bringing up the lower thread. Visual references guide you through adjusting the thread tension and managing the feed-dog. Further chapters describe presser foot selection alongside needle compatibility, specifically focusing on the 130/705H system requirements for varying fabric types like jersey, woven materials, and leather.

Technical Specifications and Maintenance

The documentation provides specific stitch settings for practical workshop applications. Having these exact factory baselines on the bench eliminates guesswork, directly reducing diagnostic time for mechanics and DIYers. Technical parameters highlight a 4 mm maximum zig-zag width and specify a 15W light bulb for standard illumination. You will find needle-to-thread pairing charts, alongside essential maintenance advice for hook lubrication and stitch plate cleaning. Thread tension is adjustable via a marked wheel, with reference points documented for standard sewing tasks. Specifications for needle clearance and insertion depth help maintain precise timing.

To save on expensive mechanic visits, the manual provides specific step-by-step instructions for routine servicing. It outlines exactly how to properly remove the free-arm cover, extract the hook, clean the hook race, and lubricate the assembly to resolve slow motor speeds or persistent thread jamming. Additionally, troubleshooting tables offer fast solutions for common issues like thread breakage or slow motor performance. Please note: To ensure safe operation, always disconnect the power supply before maintenance and consult a certified technician before attempting any internal electrical or mechanical repair.

Restore your Bernina’s performance with the original factory-authorized service procedures.and minimize machine downtime.