Husky 545 Rebuild (First Post) - long winded.. sorry

[bryanr2]

Has anyone out there done a bolt-on swap with the 550xp p/c on a 545 case? The IPLs seem to tell me that all the intake parts are the same.

@Mastermind did the transplant for me. I sent my nos 550xpg and we used a nos 545 case along with the 545 clutch cover and converted everything over to orange. Randy can fill us in. I know there was some little issue, but I can't remember what it was.

 

[CoreyB]

I tried looking through the bulletins this morning and could not find it. I must have confused it with a different modle. but I swore it was the 550 545.

 

[Tor R]

Thanks Tor! I'm surprised that the saw would even run with a huge air leak. I will do a vacuum/pressure test when it's back together. Hhhmmm, you have me wondering if that would explain why the internals were so oily and the carbon came off the top of the piston so easily. Maybe their was a huge air leak and the Autotune was just pouring fuel in?

I'm not saying you have lean issue on your 545, the way you describe your 545 make me more think of fuel mix and not to forget if they swapped the fuel.
I've seen that carbon cake come loose when we swap from pump fuel over to alcylate fuel.
I expect my 550 xpg 2012 to have a blasted PTO bearing, but it for sure made me think a bit yesterday

 

[Mastermind]

@Mastermind did the transplant for me. I sent my nos 550xpg and we used a nos 545 case along with the 545 clutch cover and converted everything over to orange. Randy can fill us in. I know there was some little issue, but I can't remember what it was.

I tried to use the stuffers on the 545 crank........that was a no go.

 

[Dirtmagnet]

I'm not saying you have lean issue on your 545, the way you describe your 545 make me more think of fuel mix and not to forget if they swapped the fuel.
I've seen that carbon cake come loose when we swap from pump fuel over to alcylate fuel.
I expect my 550 xpg 2012 to have a blasted PTO bearing, but it for sure made me think a bit yesterday

Yep, understood. It was good thinking for sure and I appreciate it.

BTW, does the 545/550xp use the same PTO bearing as a 346xp? Wasn't there something about a 346xp PTO bearing being a combination of bearing and seal and expensive or something? I have a Husky 353 (love this saw!) but have never had it apart.

 

[Tor R]

I tried to use the stuffers on the 545 crank........that was a no go.

I've never gone so deep into 545, so we cant buy 550 stuffers and put them on a 545 crank?

 

[Tor R]

Yep, understood. It was good thinking for sure and I appreciate it.

BTW, does the 545/550xp use the same PTO bearing as a 346xp? Wasn't there something about a 346xp PTO bearing being a combination of bearing and seal and expensive or something? I have a Husky 353 (love this saw!) but have never had it apart.

I thought it was the same bearing as used on 346.
Husky has updated 545/550 PTO bearing twice, I'm not sure if they're done yet, I saw one 550xpg who had blasted both flywheel & PTO bearing, running time 12 minute.
Me think they should trow this plastic ball cage out of the window and go back to how they made those special PtO bearings in the old time.

 

[Dirtmagnet]

I thought it was the same bearing as used on 346.
Husky has updated 545/550 PTO bearing twice, I'm not sure if they're done yet, I saw one 550xpg who had blasted both flywheel & PTO bearing, running time 12 minute.
Me think they should trow this plastic ball cage out of the window and go back to how they made those special PtO bearings in the old time.

12 minutes?? That's digusting..

 

[Tor R]

12 minutes?? That's digusting..

according Husky Norway, 1 out of 800 has this fate.
They last a few minute and the ball plastic cage is gone, I saw the bearings and the AT running time at my dealer

 

[Mastermind]

I've never gone so deep into 545, so we cant buy 550 stuffers and put them on a 545 crank?

The crank in the 545 is about .040 wider than the one in the 550.

 

[Onan18]

After awhile of running with an air leak they go into a mode I call "GFY, I'm not running like this any longer". lol

Repped

 

[Spike60]

Stock gasket for these saws is .030. You can make a .010 gasket and get the squish you are looking for, but like the guys say you can't go with a no gasket build on these saws.

There are some reset options with the AT, and you should do them if you can. There is a fuel system reset that can be done at any time. For a full rebuild like you are doing the "master reset" is the way to go. Maybe more important is to do a firmware update before you run it. It seems like every time I'm using the CST it downloads new firmware files from the mother ship, so it's likely that there have been changes to what you have in your AT module right now. The carb doesn't have to be in the saw to do any of this; in fact it's easier out of the saw. But you do need to have the part number off the coil as this must be entered when doing the update.

 

[weedkilla]

I ran a thinner base gasket in a 550 to get squish to 020, I had to clearance a couple of spots on the case.

 

[Dirtmagnet]

Stock gasket for these saws is .030. You can make a .010 gasket and get the squish you are looking for, but like the guys say you can't go with a no gasket build on these saws.

There are some reset options with the AT, and you should do them if you can. There is a fuel system reset that can be done at any time. For a full rebuild like you are doing the "master reset" is the way to go. Maybe more important is to do a firmware update before you run it. It seems like every time I'm using the CST it downloads new firmware files from the mother ship, so it's likely that there have been changes to what you have in your AT module right now. The carb doesn't have to be in the saw to do any of this; in fact it's easier out of the saw. But you do need to have the part number off the coil as this must be entered when doing the update.

Thank you Spike. I haven't checked squish yet, so I appreciate everyones input. I may end up using a base gasket for simplicity. I have a new one coming anyway.

1. On the topic of the AT reset, is there a way that the average consumer can do this without software (other than running the saw WOT under load for 5-6 cuts)?
2. If the software is required (with its cable) can we purchase this and use it for reset?
3. I believe I have heard that only dealers have access to firmware updates even if a consumer purchases the software/cable. Is this true? And if so, how can I update the firmware? I bought the saw used and I don't think any local dealers would be kind enough to help me..

Thanks again to everyone for their input. It has been very helpful.