Well it took just shy of forever, but the 254xp is finally done. With constant back orders and a late decision to convert it over to air injection were the main culprits. After a last minute muffler job, I took it out to the wood pile for a few cuts in the dark. This really made this saw wake up, was glad to get permission to do so, as it really cut quite well. I can see now why this saw is so revered.
Parts came from HL Supply
@Gentleman, Husqvarna, Bailey's, Chainsawr, Pantano, FarmerTec, and a couple of gracious members
@Toad22t ,
@backhoelover that deserve an extra special thank you for there help. Also speaking of help many members here helped with all manor of things especially timing numbers and such, too many to list individually so just a big thank you to all the site members here.
The build was fairly straight forward, with the exception of the cases being re-painted wit Husqvarna paint. SKF bearings were installed with new Husqvarna seals. Oiler worm drive gear and drum were updated to newer style. Both Intake and exhaust ports were smoothed and matched to the manifold and muffler before polishing. A thin .020" base gasket was used to bring the squish down to .021"-.022". Finished off with the last minute muffler mod, other wise everything else was pretty much just R&R.
The air injection for any one wishing to update the older saws is not as straight forward or as easy as it would seem, the exhaust deflector being the exception, that goes right in behind the muffler, no sweat. The moon shaped air deflector that goes on the crankcase had to be marine epoxied to the case as the case had no place to mount the screws. A newer top cover is necessary as well as the air foil behind the starter and even the starter was updated as believe it or not has a different way the air enters into it. It also had to have every last part in it replaced as nothing from the older starter would fit. So quite part heavy and about half of them are NLA as well.
The clutch cover is for the newer models and a little alignment stub had to be ground off to allow it to fit the older case. A new sticker for a 272xp was cut down to fit the clutch cover.
A narrow kerf, narrow gauge chain was installed, this I've found works quite well with the 50cc class of saws, really does make 'em cut faster, and at 20" is lighter as well.
Original parts that were re-used. Cases, crankshaft, carburetor, tank handle, muffler, oil pump and screws. That's it, everything else is new, even the bar studs and chain tensioner were replaced. I was also able to salvage the 300th year sticker and put it on the top cover.
But it's done now and its owner is happy, so I reckon that's all that matters. Now he can go beat the snot out of it.
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