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Husqvarna 455 Rancher Workshop Manual
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Husqvarna 455 Rancher Workshop Manual

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Workshop manual
455 Rancher 460
English

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Summary of Contents for Husqvarna 455 Rancher

  • Page 1 Workshop manual 455 Rancher 460 English...

  • Page 2: Table Of Contents

    Workshop manual Husqvarna 455 Rancher and 460 Contents Introduction ............3 Safety regulations ..........4 General instructions ........... 4 Special instructions ..........4 Special tools ............5 Technical data ............7 Carburettor ............9 Carburettor ............9 Carburettor - pressure testing ......14 Carburettor - adjustment ........

  • Page 3: Introduction

    1. Look up the page referring to the relevant sub- assembly. 2. Follow the instructions under the headings: This workshop manual covers the following chainsaw models: 455 Rancher • Removal/Dismantling • Cleaning and inspection • Refi tting/Reassembly...

  • Page 4: Safety Regulations

    Safety regulations Safety regulations General instructions Special instructions This workshop manual gives detailed instructions The fuel that is used in a chainsaw poses the fol- on how to troubleshoot, repair and test a chain- lowing hazards: saw. This section also describes the various safety precautions that should be taken when carrying out •...

  • Page 5: Special Tools

    Special tools Special tools English –...
  • Page 6 Special tools Item Description Used for Order no. Clutch tool Centrifugal clutch 502 54 16-01 Piston stop Locking the crankshaft 504 91 06-05 Fuel fi lter hook Withdrawing the fuel fi lter 502 50 83-01 Allen key For M5 bolts 502 50 18-01 Pressure tester Pressure testing cylinder...

  • Page 7: Technical Data

    Technical data Technical data Displacement Cylinder bore Stroke Max power/speed /cubic inches Ø mm/Ø inches mm/inches kW/hp/rpm 455: 55,5 / 3,38 47 / 1,85 32 / 1,28 2,6 / 3,5 / 9 000 460: 60,3 / 3,68 49 / 1,93 32 / 1,28 2,7 / 3,7 / 9 000 Spark plug gap...
  • Page 8 Technical data Idling speed Engagement speed Spark plug 455: 2 700 3 800 NGK BPMR 7A Champion RCJ 7Y 460: 2 700 3 800 NGK BPMR 7A, Champion RCJ 7Y Fuel tank capacity Oil pump capacity at Oil tank capacity Automatic oil pump Litres/US pints 8,500 rpm,...

  • Page 9: Carburettor

    Carburettor Carburettor Carburettor The mixing venturi (B) houses the choke, throttle valve and diffuser jets. Here air is mixed with the WARNING! fuel to give a fuel/air mixture that can be ignited by The fuel used in the chainsaw has the ignition spark.
  • Page 10 Carburettor Function In the part throttle mode (see fi gure below) the th- The carburettor operates differently in the following rottle valve (I) is partially open and the choke valve modes: (H) is open. Fuel is supplied through the diffuser jets (D and E).
  • Page 11 Carburettor Carburettor – removal Loosen the screws (x4,D) on the carburettor. Lift the carburettor out of the carburettor compartment. NOTE! Do not use knurled pliers to disconnect or reconnect the fuel hose. This could damage the hose and lead to leakage or fracture. Remove the cylinder cover and air fi...
  • Page 12 Carburettor Cleaning and inspection Remove the cover (J) over the pump unit and WARNING! carefully remove the gasket (I) and pump diaphragm Fuel has the following hazardous (G). See fi gure below number 8. properties: 1. The fl uid and its fumes are poi- sonous.
  • Page 13 Carburettor Assembly Where no fi gure is referred to, see fi gure on the Fit the needle valve (D) with lever (C), pin and previous page. spring and tighten the screw (E). Fit welch plug (K). See fi gure below. Maintain a high level of cleanliness when assem- bling the carburettor.

  • Page 14: Carburettor - Pressure Testing

    Carburettor Carburettor – refi tting Fit the air shutter blade on the shaft (L) and con- NOTE! nect the throttle actuator rod (N) in parallel with the ordinary throttle valve. The valve housing (P) is Cleanliness is very important when reas- secured in the carburettor using two screws.

  • Page 15: Carburettor - Adjustment

    Carburettor Basic adjustment for EPA II saws with capsed • Mount, for this model, approved bar and carburettors chain combination (see Technical data in the Model 455 and 460 are equipped with capsed Operator's Manual). carburettors. A slightly different adjustment proce- 455 16"...
  • Page 16 Carburettor 5. Let the engine run at ”B” rpm ~ 1 minute, until 7. Adjust the L-needle until the highest possible warm. idling speed is achieved and then turn the L- needle 1/2 turn counterclockwise. Use a narrow blade screwdriver (ref.no. 531 00 48-63) and 6.

  • Page 17: Troubleshooting

    Troubleshooting Troubleshooting The various faults that can affect a chainsaw are divided into four groups. In each group the likely symptoms are given on the left and possible causes are listed on the right. The most likely faults are given fi rst, and so on. Starting Idling (low rpm) (cont.) Diffi...
  • Page 18 Troubleshooting High rpm Acceleration and retardation Will not run at Adjust H screw Does not Adjust L screw full throttle Blocked air fi lter accelerate Adjust H screw Blocked fuel tank vent Blocked air fi lter Blocked fuel fi lter Blocked fuel tank vent Fuel line blocked Blocked fuel fi...

  • Page 19: Repair Instructions

    Repair instructions Repair instructions Chain brake – dismantling WARNING! Make sure the spring does not fl y Disengage the brake by pushing the kickback out and cause injury. Wear eye guard backwards. Unscrew the guide bar bolts and protection. remove the clutch cover, chain and guide bar. Remove the screws and carefully remove the cover from the chain brake spring.
  • Page 20 Repair instructions Chain brake – reassembly Tension the brake spring by using the kickback guard from the saw as a tool. Engage it with the Bolt the elbow joint to the brake band and tighten brake mechanism and turn clockwise to release the to a torque of 1–1.5 Nm.

  • Page 21: Silencer

    Repair instructions Silencer – removal Silencer – refi tting WARNING! If the saw is equipped with a spark arrestor mesh Do not touch the silencer until it this should be fi tted fi rst. has cooled down, otherwise you may burn yourself. Refi...

  • Page 22: Stop Switch

    Repair instructions Stop switch – removal Cleaning and inspection Clean and inspect all parts carefully. If there are any cracks or other defects replace the damaged Remove the cylinder cover and air fi lter. parts with new ones. Always use original parts. Stop switch –...

  • Page 23: Choke Control

    Repair instructions Stop switch – refi tting Choke control – removal Carefully press the new stop switch into place. Remove the cylinder cover, air fi lter and stop Check that the switch’s upper mounting clips over switch. the air fi lter holder. Tilt the carburettor.

  • Page 24: Throttle Trigger

    Repair instructions Choke control – refi tting Throttle lock, throttle trigger and return spring – refi tting First reattach the choke control to the air fi lter holder, then press it onto the carburettor so that the clips engage. Refi t the return spring to the throttle trigger as shown.

  • Page 25: Starter Assembly

    Repair instructions Starter assembly – removal Replacing a broken or worn starter cord Undo the four bolts that fasten the starter assembly Before replacing a worn starter cord the tension in the to the crankcase and lift off the starter assembly. recoil spring must be released.

  • Page 26: Recoil Spring

    Repair instructions Replacing a worn recoil spring Cleaning and inspection • Clean and inspect all parts carefully. If there are WARNING! any cracks or other defects replace the dama- Make sure the recoil spring does ged parts with new ones. Lubricate the return not fl...

  • Page 27: Ignition Module - Testing

    Repair instructions Ignition module – testing If replacing the ignition module, disconnect its leads If there is a fault in the ignition system the ignition and unscrew it. The ignition module can be left in module must be tested before the ignition system place if you are simply removing the fl...
  • Page 28 Repair instructions Ignition module and fl ywheel – refi tting Then refi t: • cable guide and press the leads into position Place the fl ywheel on the crankshaft. Turn the • HT lead fl ywheel so that the key lines up with the keyway in •...

  • Page 29: Centrifugal Clutch

    Repair instructions Centrifugal clutch – removal Inspection and cleaning • Clean and inspect all parts carefully. If there are any cracks or other defects replace the dama- Remove the cylinder cover. Disengage the chain ged parts with new ones. Always use original brake by pushing the kickback guard backwards.

  • Page 30: Oil Pump

    Repair instructions Unbolt the oil pump from the crankcase and Remove the piston stop. Fit the spark plug, tightening remove it together with the oil pressure hose. it to a torque of 15 Nm, then connect the HT lead. Then refi t: •...
  • Page 31 Repair instructions Cleaning and inspection • Clean and inspect all parts carefully. If there are Bolt the oil pump to the crankcase. It must be bol- ted to a torque of 2–3 Nm. Replace the oil pressure any cracks or other defects replace the damaged parts with new ones.

  • Page 32: Air Intake System

    Repair instructions Adjustable oil pump – adjustment Remove: Use a screwdriver to turn the adjuster screw on the • cylinder cover pump. Turning the screw clockwise decreases the • air fi lter oil fl ow and turning it anti-clockwise increases the oil fl...

  • Page 33: Fuel Fi Lter

    Repair instructions Replacing the fuel fi lter Place the new cylinder base gaskets on the crank- case. Fit the cylinder on the crankcase by pressing NOTE! the cylinder gently down onto the crankcase and Do not use knurled pliers to disconnect or then carefully turn the saw so that the cylinder reconnect the fuel hose.

  • Page 34: Fuel Tank

    Repair instructions Fuel tank vent Tank vent replacement Pull out the tank vent with a pair of knurled fl at The two-way valve has the following properties: • Has a controlled opening pressure outwards and pliers. inwards that prevents overpressure and under- pressure arising in the fuel tank, which can affect the engine.

  • Page 35: Decompression Valve - Pressure Testing

    Repair instructions Remove the bearing from the little end of the con- necting rod. • Measure piston ring wear. This should not If replacing the cylinder: exceed 1 mm. Use the piston to push the piston Remove the intake manifold, see “Air intake sys- ring for correct alignment.
  • Page 36 Repair instructions Piston and cylinder – refi tting Lubricate the piston ring and piston with two-stroke oil. Lubricate the little end bearing with two-stroke oil and insert it in the connecting rod. Fit new cylinder base gaskets. Lower the cylinder over the piston carefully.

  • Page 37: Cylinder - Pressure Testing

    Repair instructions Crankshaft complete - dismantling Cylinder – pressure testing Remove the following: • chain and bar • clutch cover • cylinder cover • starter assembly* • centrifugal clutch* • throttle pushrod • carburettor* • silencer* • handle system • hand guard •...

  • Page 38: Crankshaft Bearings

    Repair instructions Crankshaft bearings – replacement Crankshaft complete – reassembly Remove: • The crankshaft complete from the crankcase. Fit the crankshaft complete in the crankcase. Refi t the following parts: • piston and cylinder* Pull the crankshaft bearing off of the crankshaft •...

  • Page 39: Thread Insert

    Repair instructions Repairing damaged threads Pull the steel wire until the bolt comes out through A repair kit, 503 27 33-01, is available for repairing its hole. damaged threads. First drill out the hole using: Pull through the bolt with its nut. Place a spacer between the nut and crankcase.
  • Page 40 114 02 92-26 2005W22 English –...

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