Husky 545 Rebuild

[Dirtmagnet]

Hi everyone. Here is the 545 i picked up from eBay. It's a 2012 model that ran, but had a stuck (carboned up) ring. Since the ring was stuck, I decided to tear off the cylinder and make it right. This is going to be my first Autotune saw and used for general firewood duty. On to the pics.

Since the ring was stuck, there was quite a bit of blow-by. Here are the pictures of the piston after I cleaned it up using (carefully) green Scotch brite to remove excess carbon build up.

Here is the exhaust side of piston - a bit of wear but nothing excessive that can be felt with a fingernail.

Top of the piston (obviously OEM thankfully)

Here is the cylinder cleaned up with a Scotch brite. Looks good! Yay! All thats left is to clean the exhaust port and finish cleaning.

 

[Dirtmagnet]

Here is the Carb. Original AT-1. Hopefully the carb is not the reason the ring stuck.



Here is the "modified" muffler that it came with. I will open it up a bit.



I don't have much time right now, so this build will go a bit slowly, but i will try to keep updated as I go.

 

[Dirtmagnet]

Ok. Finally got back to this. Work and life have sucked the time out of me.. Here it goes.

Got around to opening up the muffler some. Wasn't trying to get crazy, just get some heat out and let the saw breath.





Then I started working on the carb. Decided to put a kit in it for good measure.



It was in need for sure. The plastic pump side gasket had the 'flaps' a bit raised.



And the fuel feed side diaphragm was REALLY stiff.. It was the worst i've ever seen.

 

[Dirtmagnet]

Next, I checked the needle height before removal.



It's difficult to see from the photo, but there is a gap of around 0.020" from the carb surface. Does anyone know if this is correct?

Then i tried to remove the needle, but that darn screw would NOT budge.. I have to leave it for now and hope it works. Getting the screw out isn't difficult, but replacing the screw is another matter..



And finally for tonight, the carb gets its bath



That's all for now. I will continue as time permits!