Husky 550xp 545 w/ complete 562xp Intake & Carb

[Flip]

Lets get the Legalese out of the way:

YouTube Saw Builder Warning: No Hyway products were harmed during the modification of this saw.

The main reason for this thread is to be able to pull a 18" 3/8 bar & chain on a 50cc with authority in hardwood.

I'm a big fan of these new strato saws, they make good torque while sipping gas. The only thing I don't like is you can't mod them like you did the 3 series. Started looking to see if you could upgrade the intake/carb/filter setup like you could on the old saws.
All the pictures are 545 on left 562xp on right.

Cylinders:

Intake

Filter holder/air intake

545 & 555 Filter

 

[Flip]

So everything mostly lines up and most importantly, the locating pins on the 562 intake(Inlet pipe) line up on a 550xp cylinder. I ordered a new 545 since I can't have my 550xp apart during the winter. I also order the following items:

562XP:
Inlet Pipe 520291001
AT55a Carburetor (replaces EL48) from H&L Supply
Flange 505165201
Filter Holder Assembly 505127003 swapped over the switch & air purge hardware from 545

550XP:
Intermediate Wall 522951001

560XP:
Air Filter 505126306

 

[Flip]

I traced the 562 intake onto the 545 cylinder. Pretty good difference.



I didn't want to do any porting yet so I just blended in the intake port to fit the intake tract and egged out the screw holes to fit the 545 cylinder. The idea was the extra mix would increase velocity lost by not having stuffers. I left the strato ports alone because I didn't want to change the timing or length of the strato charge.

 

[Flip]

You can see from the first post that the intake tract uses raised rubber ridges to seal the tract to the cylinder. It looks like everything seals up.


I wanted to make sure so I made some gasket out of 1/32 Fel-Pro material. I also made a thinner cylinder gasket out 1/64 material which gave me a squish of .21. Also clearanced the cylinder skirt for the thinner gasket.


Should seal up now. Also had to clearance the 550xp intermediate wall for the bolt hole. It fit great after that.


The 545 & 562 look like they both use the same AutoTune module, I just swapped the 545 module onto the 562 carb.

 

[Flip]

Putting the saw back together, everything went in like factory. The new short fuel line that comes up straight out of the tank make reassembly as easy as a 3 series Husky I think.
Final assembly pics



Top cover on mine closes without any need for any trimming anywhere.

Here is the final product.

I personally like the grey clutch cover. It says to everyone that there's an adult in the room now that may or may not have performance issues.

 

[Flip]

How does it run? I grew up on an family farm where nothing was wasted so I've never cut a cookie or cared about timed cuts. I go by how I like the feel and the power.

I cut up a white oak that was blown down in a storm last may. I ran this saw and my 2015 550xp with the same bar & chain(68dl hand filed Stihl RS), modded muffler and thinner cylinder gasket. It wasn't even close.

The 550xp had to monitored closely to keep up the RPM's. The 545 could be dogged in while the bar was buried. It was pretty amazing considering it was on it's first tank.

I'll also note that the 545 AutoTune module on the 562 carb has had no issues. It fired right up and has been trouble free in the 2 months I've been using this saw.



Let me know what you think!

 

[Funky sawman]

?

 

[Flip]

?

Working on it.

 

[kingOFgEEEks]

Oooh. You might be onto somethin here. I'm subbed to see what's what.

 

[sawmikaze]

Cool.

 

[ammoaddict]

Subbed

Sent from my Moto G (4) using Tapatalk

 

[srcarr52]

Next project... 562 with rev boost?

 

[Flip]

Next project... 562 with rev boost?

I'm thinking the same thing too.

Really want to try to put a 572 setup with a 565 filter on my 562 but that new 572 stuff is crazy expensive right now.

 

[cuinrearview]

 

[Spladle160]

Nicely done!

 

[Flip]

Thanks for the 550xp cylinder. I didn't want to hack up a brand new OEM cylinder if it didn't work out.

 

[cuinrearview]

Thanks for the 550xp cylinder. I didn't want to hack up a brand new OEM cylinder if it didn't work out.

Glad it went to a good cause. We're gonna a need some video of course

 

[Flip]

Glad it went to a good cause. We're gonna a need some video of course

I got a couple more big oaks that need to be bucked up and I'll shoot some vid's. Every time I run this thing it amazes me.

 

[JohnnyBlade]

Nice work Flip. This is cool stuff!
Videos r a must

 

[Flip]

Here's the weight before the first fill up. 11.03 lbs