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I have a Husqvarna Opal 650 machine that was just purchase in July. I am hired to sew headbands, and we use Coats Transparent polyester thread. It's worked perfectly, until last Saturday it suddenly decided to break the top thread every time I backstitch (which occurs 4-6 times in the making of one headband.) It sews fine down the end, and as soon as I hit backstitch, it takes one stitch and snaps. If I come down, stop, go backwards, stop, and go forward again, it works. But I can't do it continuously. I cleaned the bobbin case, took the spool and bobbin out and re-threaded the top and bottom threads with the manual and changed the needle twice. (Actually, I had just changed the needle, and then it started happening) I made sure the needle was properly inserted, and the tension is the same as it's always been. Any suggestions? Thanks!

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Change the needle again, the needle could have a burr
check for burrs in the needle plate area and in the bobbin area
is the needle the right one for the fabric being sewed? was the needle inserted correctly into the needle holder?
is the tension correct for the fabric being sewed?

Posted on Oct 31, 2013

Testimonial: "I don't know how to tell if the needle is correct for the fabric or how to tell if there are burrs. The needle was correctly inserted, that much I do know. :) I actually took it in to be repaired, and now that it came back it skips stitches like crazy, so now I have another problem to fix. :P"


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I have a B350, i want to sew with just straight ordinary stitch, but the top stitch is too lose, the bottom stitch looks great. IN other words, i can pull the top thread out without any problem.

You need to tighten the upper tension--higher the number, the tighter the tension. Be sure you are using the appropriate needle and thread for the fabric being sewn.

If using 100% polyester thread, be sure it is a good brand--not Coats & Clark, bargain bin threads, or old thread.

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Needle stitch fine. Bobbin stitch loops.

First, try a brand new needle.

Second, consider using a better quality thread. By all means, AVOID old or bargain bin threads. Coats & Clark used to be a standard, but thread quality has improved over the past few years, so you may want to check out other brands like Aurafil, Superior, Isacord, etc. Also, cotton wrapped polyester thread releases thread lint that contributes to build-up of gunk in the machine. Some sewists have noted that they experience more sewing issues when using C&C threads. However, some machines will do better with certain thread brands than others, so some experimentation may be beneficial.

Third, check the stitch on your sample again. Generally, when thread loops appear on the underside of the fabric, it is the upper thread that is the problem. If loopy threads appear on the top of the fabric, it is the bobbin thread that is the issue. You can even use a different color in the top to help distinguish which thread is the problem.

Fourth, when threading the upper thread, Always Raise the Presser Foot during the threading process so the tension disk is released and the thread can seat properly. "Bird nesting" occurs when the thread is not seated in the tension disk.
Sewing Machine Thread Bunching Up Here Why

Birds nest under the fabric big loops of thread top side looks good...

Fifth, when the upper thread appears on the underside of the fabric, the upper thread tension is too loose. If the bobbin thread appears on the top of the fabric, the tension thread is too tight (or the bobbin thread is loose). Start out with the upper tension set at the midway point and tweak it from that point. The tension is ideal when both upper and bobbin threads meet in the middle of the fabric.

Also, remember that tension is not static--a tension setting for chiffon will most likely not work on cotton or denim. Get comfortable adjusting the tension to suit the project you are sewing.


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Says check upper thread, but thread not broken. then stitches about 20 stitches and stops again

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Calmly let them know that it used to do this and now it won't. Maybe they can take care of the problem for you.
If they are not willing to help, take all of the repair documentation that you have on what was done and contact another Husqvarna Viking dealer to see if they can help.

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Probably just too heavy for the machine to handle and the thread may also be too thick for the bobbin to tension correctly.

Thread above 50 gauge is not suitable for domestic sewing machines and it is likely that that is what the shade cloth manufacturer use through an industrial machine.

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Try moving the stitch length dial to 4 or 5 - check the manual. You may have it in the position for very close together sewing. I had to do a lot of trying with my 4795 to get it to work right. I found that very thin thread, polyester kind, broke at the needle after a couple of stitches. I switched to coats & clarks thread and a Singer ball point needle and it works fine. Be sure your needle is inserted with the flat top toward the back of the machine. Good luck!

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