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This could be bad timing, or the needle is not in properly. Make sure that the needle is pushed up all the way, and in the correct position. If the needle is too low, it will break. Also, keep the bobbin case door open to see where the needle is catching.
A sewing machine operator can often help themselves when their machine does not operate properly. Here are some simple instructions, which if properly used can save time and mechanics service calls. TROUBLE;UPPER THREAD KEEPS BREAKING; This could be trouble;================Do this; 1.Top tension to tight================loosen tension 1 turn 2.Machine improperly threaded=========check threading 3.Thread twisted on guide post========" 4.Thread twisted out of tension=======" 5.Take up spring bent or broken=======Check action of spring 6.Thread jumped off pull off finger===Check threading 7.Needle bent or burred===============new needle 8.Bad cone of thread==================try another cone TROUBLE;LOWER THREAD KEEPS BREAKING; 1.Bobbin tensionspring to tight=======Loosen tension slightly 2.Bobbin threaded wrong===============check threading 3.Bobbin wound to tight or uneven=====try new bobbin 4.lint or thread on bobbin case=======clean inside case 5.Lint or thread inside hook==========clean inside hook 6.Bobbin case nicked bent or burred===check/change case TROUBLE;MACHINE STARTED SKIPPING STITCHES; 1.Needle bent or burred===============change 2.Needle set in crooked===============Check 3.Thread jumped off take up spring====check threading 4.Thread jumped off pull off finger===check threading TROUBLE STITCHES SHOWING LOOPS; 1.Forming loops on top of cloth=======Tighten bobbin tension ======================================or loosen top tension. 2.forming loops on bottom of cloth====Tighten top tension 3.Bobbin placed in case incorrectly===remove and replace 4.Bobbin thread slipped from under====check threading of tension===============================bobbin case 5.Lint or thread in top tension=======clean between tension discs
sounds like the sewing head is out of line. Suggest that it be serviced by an authorized Husqvarna Viking Dealer. You can find the nearest dealer by click on the "Dealer" link at http://www.husqvarnaviking.com
Check that it is threaded correctly (both top and bottom) making sure that the upper thread is in the takeup lever. Watch the needle as you slowly turn the handwheel counter clockwise (toward you) and the needle point touches the fabric (make sure presser foot is down). Is the thread still relatively taunt? If it is loose, the upper thread tension unit does not have enough tension. Check the areas where the thread goes and make sure you remove any loose threads or fluff which could be inhibiting the tension discs from closing over the thread. If the tension unit still is not tightening enough, the tension unit may need to be replaced or the circuit board replaced. If everything is ok in the upper thread area, now look at the bobbin area. With no fabric, watch as the needle enters the bobbin area. Does it go down and the upper thread catch the bobbin thread and pulls it to the surface? Check for anything preventing the bobbin thread from being pulled up to the surface through the needle plate. If you have still not been able to resolve the problem suggest you take it to an authorized husqvarna viking dealer for service. You can locate a dealer near you by visiting the husqvarna viking website and clicking on the Dealer link on the left-hand side of the page - http://www.husqvarnaviking.com Good luck.
* Your broken needles may have been too thin for your fabric. Make sure your replacement needle is appropriate for the weight and type of your fabric and thread. You may also need a thicker needle if you’re sewing through bulky layers of fabric. * When you insert your new needle, make sure it’s positioned correctly (usually with the flat side away from the bobbin, but consult your manual), that it goes all the way into the holder, and that the screw is securely tightened. If this doesn’t seem to be the problem
* Check your pressure foot Make sure it’s attached securely. * Change your pressure foot Your pressure foot may be bent, causing your needle to hit it. * Don’t sew over pins A needle that hits a pin can break. Always remove the pins from your fabric before they reach your needle. * Don’t pull your fabric as you sew You could be bending your needle back, causing it to hit your needle plate instead of going into the hole. Just guide your fabric, letting it feed on its own. * Check your needle plate Make sure it's securely in position. * Change your needle plate If you’ve been using a straight stitch needle plate (a plate with a small hole, often used for sewing fine, delicate fabrics), switch to a needle plate with a wider hole. * Check the position of your needle Sewing machines with zigzag capability allow you to adjust the position of your needle – right, left, or center. If your needle is not positioned correctly, it may be hitting your needle plate or pressure foot.
If possible hoop the item. I have found that any item that has any thickness causes the presser foot to be pushed forward and the needle hits it and breaks. If you can press the item to lessen the thickness this may help. I spoke to Singer (I am a Singer dealer) and they did not have any help for this other than to recommend that the owner cut out the back of the foot. I don't think that would be a solution as it would be difficult to cut out the back of the foot and still have smooth edges, also it would cause the foot to be weak and possible break or bend. Good Luck
When topstitching using straight stitch the needle position can be adjusted in steps. The stitch width button(+), 0 is the center position, width 6 isleft needle position,width6 mirror image(diamond half clear and half black)is right needle position.
hope this helps, it is from the manual.