Husqvarna 545 Mark II Workshop Manual
  1. Manuals
  2. Brands
  3. Husqvarna Manuals
  4. Chainsaw
  5. 545 Mark II
  6. Workshop manual

Husqvarna 545 Mark II Workshop Manual

Hide thumbs Also See for 545 Mark II:
Table of Contents

Advertisement

Quick Links

Workshop manual
®
545 Mark II, 550 XP
Mark II,
®
545G Mark II, 550 XP
G Mark II
English
722 - 003 - 26.03.2019

Advertisement

Table of Contents
loading

Related Manuals for Husqvarna 545 Mark II

Summary of Contents for Husqvarna 545 Mark II

  • Page 1 Workshop manual ® 545 Mark II, 550 XP Mark II, ® 545G Mark II, 550 XP G Mark II English 722 - 003 - 26.03.2019...

  • Page 2: Table Of Contents

    5.2 Servicing data............10 8.22 Thermostat and heating element....... 68 8.23 To repair a damaged thread.......69 6 Servicing tools ® 6.1 Servicing tools for 545 Mark II, 550 XP Mark 9 Troubleshooting ® II, 545G Mark II and 550 XP G Mark II......12...

  • Page 3: Introduction

    1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from Husqvarna. 722 - 003 - 26.03.2019 Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions • Make sure that the chain brake is engaged when you remove the pressure spring on the chain brake. Warnings, cautions and notes are used to point out If the chain brake is not engaged, the pressure specially important parts of the manual.
  • Page 5 yyyywwxxxx The rating plate shows se- rial number xxxx. yyyy is the production year and ww is the production week. Note: Other symbols/decals on the product refer to certification requirements for some markets. 722 - 003 - 26.03.2019 Safety - 5...

  • Page 6: Prepare And Do Servicing On The Product

    3 Prepare and do servicing on the product 3.1 Maintenance schedule Daily maintenance Weekly maintenance Monthly maintenance Clean the external parts of the prod- Clean the cooling system. Make sure Do a check of the brake band. uct and make sure that there is no oil to clean the flywheel wings.

  • Page 7: Technical Data

    4 Technical data 4.1 Technical data Cylinder displacement Cylinder bore Stroke Max. power/rpm Model /cubic inch Ømm/Øinch mm/inch kW/hp / rpm 545 Mark II 50.1/3.06 43/1.69 34.5/1.36 2.7/3.6/9900 ® 550 XP Mark II 50.1/3.06 43/1.69 34.5/1.36 3.0/4.0/10 200 545G Mark II 50.1/3.06...
  • Page 8 Capacity oil pump at Volume fuel tank 9,000 rpm Model Spark plug Type of oil pump Litre/US. pint ml/min 545 Mark II NGK CMR6H Adjustable 0.53/1.12 5-12 ® 550 XP Mark II NGK CMR6H Adjustable 0.53/1.12 5-12 545G Mark II...

  • Page 9: Servicing Data

    5 Servicing data 5.1 Symbols in the diagrams Lubricate with chain oil. Lubricate with grease. Lubricate with two-stroke oil. 722 - 003 - 26.03.2019 Servicing data - 9...

  • Page 10: Servicing Data

    5.2 Servicing data * When you operate the product, this value will decrease. Examine torque, minimum 5 Nm. 9 ± 1 Nm* 18.0 ~ 20.0 Nm 16 mm 1.5 - 2.0 Nm 5.0 - 6.0 Nm 545/545G 3.0 - 4.0 Nm 1.0 - 2.0 Nm 1.0 - 2.0 Nm 3.0 - 4.0 Nm...
  • Page 11 545G/550XPG 7.0 - 9.0 Nm 5.5 - 7.0 Nm 14.0 - 16.0 Nm 17.0 - 19.0 Nm 3.0 - 4.0 Nm 1.0 - 2.0 Nm 2.3 - 3.0 Nm 6.0 - 7.0 Nm 3.0 - 4.0 Nm 1.0 - 2.0 Nm 3.0 - 4.0 Nm 7.0 - 9.0 Nm 3.0 - 4.0 Nm...

  • Page 12: Servicing Tools

    6 Servicing tools ® ® 6.1 Servicing tools for 545 Mark II, 550 XP Mark II, 545G Mark II and 550 XP G Mark II 12 - Servicing tools 722 - 003 - 26.03.2019...
  • Page 13 Item Description Use for Article number Piston stop Locking the crankshaft 575 29 36-01 Hook Suspending the fuel filter 502 50 83-01 T-handle Torx T10 For Torx screws 588 52 41-01 T-handle Torx T20 For Torx screws 588 59 85-01 T-handle Torx T27 For Torx screws 502 71 27-03...
  • Page 14 Item Description Use for Article number Thread insert MT6 screw 503 27 40-01 Thread insert MT4 screw 503 27 31-01 Thread insert M5 screw 578 12 03-01 Thread insert M5 screw 582 52 60-01 14 - Servicing tools 722 - 003 - 26.03.2019...

  • Page 15: Function Overview

    For best results and performance use Husqvarna two- stroke oil. If Husqvarna two-stroke oil is not available, use a two- stroke oil of good quality for aircooled engines. Speak to your servicing dealer to select the correct oil. 7.2.2.3 To mix gasoline and two-stroke oil...

  • Page 16: Repair Instructions

    8 Repair instructions 8.1 Product overview for repair instructions 550XPG 545G 545G 16 - Repair instructions 722 - 003 - 26.03.2019...

  • Page 17: To Clean And Examine The Product Parts

    1. Chain brake and clutch cover 18. Crankcase 2. Chain catcher 19. Guide bar bolts 3. Muffler 20. Air filter 4. Start/stop switch 21. Thermostat and heating element 5. Heated front handle 22. Cylinder cover 6. Handle and throttle trigger 23.

  • Page 18: Chain Brake

    8.3 Chain brake 3. Carefully tighten the clutch housing in a vise. Use the hand guard to release the chain brake. 8.3.1 To disassemble the chain brake WARNING: Make sure that the chain brake spring does not eject and cause injury. Use protective goggles.
  • Page 19 6. Remove the screw (D), the chain tensioner cover 8.3.2 To clean and examine the chain brake (E), the worm wheel (F), the worm screw (G), the 1. Carefully clean and examine all parts of the chain washer (H) and the o-ring (J). Remove the screw (K) brake.
  • Page 20 3. Attach the chain guide (L) and the screw (K). Attach 5. Put the clutch cover in a vise. Compress the chain the O-ring (J), the washer (H), the worm screw (G), brake spring with a wide screwdriver and push it the worm wheel (F), the chain tensioner (E) and the down with your thumb.

  • Page 21: Chain Catcher

    8.4 Chain catcher 7. Use the hand guard to tighten the chain brake spring. Connect the hand guard to the chain brake mechanism and turn clockwise to release the chain 8.4.1 To replace the chain catcher brake. WARNING: You must always replace a worn chain catcher with a new one.
  • Page 22 3. Remove the muffler (C), the gasket (D) and the heat 8.5.4 To assemble the muffler deflector (E). Remove the screw (F) and pull out the 1. Attach the spark arrester (G) with the screw (F). spark arrester (G). 2. Attach the heat deflector (E) and the gasket (D) to the 2 cylinder screws (B).

  • Page 23: Start/Stop Switch

    8.6 Start/stop switch 8.6.3 To do a function test of the start/stop switch 1. Clean the mating surfaces. 8.6.1 To disassemble the start/stop switch 2. Connect a multimeter to the blue cable and the 1. Remove the cylinder cover. cylinder to measure the resistance. The resistance must not be higher than 0.5 Ω.

  • Page 24: Heated Handles

    8.7 Heated handles 3. Remove the 2 screws (K). 8.7.1 To disassemble and assemble the front heated handle 1. Remove the screws (A) and the heated handle cover (B). 4. Remove the 2 screws. 2. Remove the switch (C) from the contact plate (D). Disconnect the wire (E) from the contact plate.
  • Page 25 5. Remove the handle from the product. 7. Remove the chain catcher to get access to the screw of the vibration damping system. Loosen the screw of the vibration damping system. 8. Loosen the screw to the vibration damping system. 6.
  • Page 26 10. If the heating elements of the carburetor has not 11. Remove the screw and pull out the rear heated been removed, disconnect the cables (A). Lift the handle. Pull out the cables. saw up carefully. Pull down the hoses through the carburetor bottom plate.

  • Page 27: Handle And Throttle Trigger

    8.8 Handle and throttle trigger ® a) On 545 Mark II and 550 XP Mark II: 8.8.1 To disassemble the handle 1. Remove the screw (A) and the handle cover (B). ® a) On 545G Mark II and 550 XP G Mark II: 2.
  • Page 28 Pull the throttle wire through the hole in the tank unit. 3. Attach the throttle trigger. ® a) On 545 Mark II and 550 XP Mark II: Push the throttle trigger (D) into the handle. Push the pin (C) into the handle to attach the throttle trigger (D) to the handle.

  • Page 29: Starter

    4. Remove the starter from the starter housing. a) On 545 Mark II and 545G Mark II: Remove the bolt (D) and washer. Lift up the pulley (E), the starter spring (F) and starter pulley (G).
  • Page 30 5. Lubricate the pawls on the flywheel. 545/545G 550/550XPG 6. On 545 Mark II and 545G Mark II: Examine the starter spring. Replace the starter spring if it is damaged. 7. On 545 Mark II and 545G Mark II: Lubricate the starter spring.
  • Page 31 545/545G 550/550XPG 4. Put the starter in the starter housing. a) On 545 Mark II and 545G Mark II: Put the starter pulley (G) against the spring cassette (M). Put the spring (F) in the starter pulley. Put the pulley (E) on the spring and attach the screw (D).

  • Page 32: Ignition System

    6. Pull the starter rope to make it straight, remove your 3. Use the knob to adjust the distance between the 2 thumb and let the starter rope wind up. electrodes to 6 mm. 7. Attach the starter (B) and the cooling air conductor (C) on the crankcase.
  • Page 33 5. Pull the starter rope handle. If a spark occurs, the 8.10.4 To replace the spark plug cap spark plug is damaged. If no spark occurs, the 1. Examine the spark plug connection. Remove the ignition module is damaged. Replace the damaged spark plug cover and make sure that the ignition part.
  • Page 34 8.10.5 To disassemble the ignition system 8. Disassemble the cable holder from the crankcase and remove the cables and the ignition module. 1. Remove the cylinder cover. 2. Remove the starter unit. 3. Remove the spark plug cable from the spark plug. Remove the spark plug.

  • Page 35: Flywheel

    6. Put a clearance gauge between the ignition module 5. Remove the flywheel nut (A). Remove the screws and the flywheel. Tighten the screw to the correct (B), pawls (C), springs (D) and washers (E). Servicing data on page 9 . torque.
  • Page 36 7. Use a wrench (J) to lock the outer socket of the 8.11.2 To assemble the flywheel screw press. Use a socket wrench (K) to tighten the 1. Attach the screws (A), the pawls (B), the springs (C), screw in the center of the screw press until the and the washers (D).

  • Page 37: Centrifugal Clutch

    8.12 Centrifugal clutch 4. Put the flywheel on the crankshaft. Turn the flywheel until the key goes into the key slot on the shaft. 8.12.1 To disassemble the centrifugal clutch Make sure that the chain brake is disengaged before you disassemble the centrifugal clutch. 1.
  • Page 38 7. Put the centrifugal clutch in a vise. Carefully remove 8.12.2 To clean and examine the centrifugal clutch the clutch shoe springs. Remove the clutch shoe 1. Clean and examine the C-spring (A), the clutch hub springs from the side that does not have text. (B), the clutch shoes (C) carefully.

  • Page 39: Lubrication System

    8.12.3 To assemble the centrifugal clutch 4. Remove the screw (A) and the guide bar plate (B). 1. Put the clutch springs on the side of the shoes without text. 2. Turn the clutch counterclockwise until it stops. Use a clutch tool and an applicable socket wrench.
  • Page 40 The figures accompanying this description do not give a fuel/air mixture that can be ignited by the ignition correspond with the carburettor on the product. They spark. show only the principle of design and function. The carburettor is based on three sub-systems: •...
  • Page 41 In idling mode, the throttle valves (I) and (J) are closed 3. Turn the knob and remove the air filter from the air and the choke valve (H) is open. filter holder. Air is sucked in through an aperture in the throttle valve and a small amount of fuel is supplied through the diffuser jet (D).
  • Page 42 5. Push the air filter holder and the carburetor slightly 8. Remove the air filter holder forward to get access to the screws with the Torx tool. Remove the 2 screws. 9. Remove the suction hose (B) and return hose (A) from the air purge bulb.
  • Page 43 11. Disconnect the throttle wire (G). Remove the fuel 14. Press down the lug to release the carburetor. hose (F). 15. Remove the carburetor from the flange. 12. Remove the 2 screws. Remove the bracket and the regulator. 13. Disconnect the thermostat wires. Disconnect the generator wires.
  • Page 44 16. Disconnect the cable connectors. 44 - Repair instructions 722 - 003 - 26.03.2019...
  • Page 45 8.14.4 Carburetor components 722 - 003 - 26.03.2019 Repair instructions - 45...
  • Page 46 2 on page 47 . ® G Mark II on page 12 . ® 10. On 545 Mark II and 550 XP Mark II: Attach the four screws and washers (A) and tighten the screws. 8.14.7 To assemble the carburetor ®...

  • Page 47: Fuel Tank

    8.14.8 To adjust the metering lever 8.14.11 To do a pressure test of the carburetor - option 2 The distance between the metering lever and the gasket surface of the carburetor housing must be 0.55 mm. 1. Block the fuel inlet. Adjust the distance if it is more or less than 0.55 mm.
  • Page 48 9. Loosen the screw in the vibration damping system. 13. Remove the screw (A) to get access to the screw of the vibration damping system. Loosen the screw of the vibration damping system. 10. Remove the two screws as the illustration shows. 14.
  • Page 49 16. Remove the tank unit. 8. Loosen the 2 screws (A) in the vibration damping system (B). 9. Remove the switch (C) from the contact plate (D). CAUTION: Be careful not to cause damage Disconnect the wire (E) from the contact plate. to the hoses when lifting the saw from the Disconnect the handle wire (F) from the contact tank unit.
  • Page 50 10. Remove the chain catcher to get access to the 13. Remove the handle from the product. screw of the vibration damping system. Loosen the screw of the vibration damping system. 11. Remove the screw (P) to get access to the screw of the vibration damping system.
  • Page 51 15. If the heating elements of the carburetor has not 16. Remove the tank unit. been removed, disconnect the cables (A). Lift the saw up carefully. Pull down the hoses through the carburetor bottom plate. Pull the throttle wire down through the carburetor bottom plate.
  • Page 52 To disassemble 1. Disassemble the fuel tank. Refer to ® the fuel tank on model 545 Mark II and 550 XP Mark II on page 47 or To disassemble the tank unit ® on 545G Mark II and 550 XP G Mark II on page 49 .
  • Page 53 7. Attach the fuel filter to a new fuel hose. 8.15.6.1 To do a pressure test of the fuel tank 1. Open the fuel tank cap and drain the fuel from the 8. Close the fuel tank cap. tank. Pull out and remove the fuel hose as the 9.

  • Page 54: Vibration Damping System

    8.16 Vibration damping system 8.17 Generator 8.16.1 To disassemble the vibration damping 8.17.1 To disassemble the generator system To disassemble the 1. Remove the tank unit. Refer to ® tank unit on 545G Mark II and 550 XP G Mark II on 1.
  • Page 55 5. Attach the cables. 8. Attach the deflection limiter. 9. Attach the handle to the product and the tank unit. Pull the wires through the hole in the handle and connect them. a) Attach the cable (A) between the generator and the heating element.
  • Page 56 10. Attach the 2 screws to the handle. 13. Attach the wires as the illustration shows. 11. Tighten the screw in the vibration damping unit. Attach the screw. Tighten the 2 screws to the correct Servicing data on page 9 . torque.

  • Page 57: Cylinder And Piston

    20. Attach the cylinder cover. 5. Remove the 4 screws and lift the cylinder. Remove the sleeves for the 4 screws. 8.17.3 Product overview of the generator cables 8.18 Cylinder and piston 8.18.1 To disassemble the cylinder and piston 1. Remove the cylinder cover. 2.
  • Page 58 8. Use a long-nosed pliers to remove the G circlip from 4. Clean the bottom of the cylinder and the bottom of the pin. Keep your thumb over the circlip to prevent the crankcase. Remove all gasket particles and dirt it from flying out.
  • Page 59 8.18.4 To examine the inlet pipe 8.18.5 To examine the piston 1. Remove the 4 screws and remove the inlet pipe 1. Make sure that the piston pin bearing is not from the cylinder. damaged. 2. Make sure that the piston pin does not have damages on the running surface for the bearing.
  • Page 60 8.18.7 To examine the piston rings 6. Put a new cylinder base gasket (E) on the crankcase. 1. Examine the piston rings for damage. Note: Make sure that the gasket has not been used 2. Replace damaged piston rings. and does not have signs of damage or wear. 8.18.8 To assemble the cylinder and piston 7.

  • Page 61: Crankshaft And Crankcase

    15. Remove the flywheel. Refer to flywheel on page 35 . 16. Remove the fuel tank. Refer to To disassemble the fuel tank on model 545 Mark II and 550 XP ® Mark II on page 47 or To disassemble the tank unit on 545G Mark II and 550 XP ®...
  • Page 62 ® 19. For 545G Mark II and 550 XP G Mark II: Remove 5. Remove the crankcase on the flywheel side from the To disassemble the the generator. Refer to crankshaft. Use the crankcase splitting tool, refer to generator on page 54 . Servicing tools on page 12 .
  • Page 63 8.19.3 To replace the seal ring 5. Use a seal ring tool to put the new seal ring in the Servicing tools on page 12 correct position. Refer to Note: Hold the outer part of the bearing when you the replace seal ring.
  • Page 64 5. Push a Torx T27 or an equivalent tool through the 8.19.5 To clean and examine the crankshaft and air channel to remove dirt. Compressed air can also crankcase be used to clean the air channel. CAUTION: Make sure that dirt and unwanted particles does not go into the crankcase and into the bearings.
  • Page 65 a) Put the guide shaft in a vise. 3. Use the rear side of the sleeve and pull the crankshaft into the crankcase half on the clutch side. b) Put the bearing on top of the guide shaft with the Pull until the crankshaft shoulder touches the main sealing up.

  • Page 66: Guide Bar Bolts

    4. Put the 2 guide bushings (F) in the crankcase half 6. Attach the 6 screws (C). Tighten them in turn to the Servicing data on page 9 . on the clutch side. Attach the gasket (G) between correct torque. Refer to the crankcase halves.
  • Page 67 3. Remove the guide bar and saw chain. 3. Pull the steel wire to pull out the guide bar bolt. 4. Hit the guide bar bolts until they fall into the oil tank. 4. Make sure that the square head of the guide bar bolt is correctly attached in the oil tank.

  • Page 68: Air Filter

    8.21 Air filter 7. Remove the air filter holder and the carburetor. To disassemble the carburetor on page 46 . Refer to 8.21.1 To remove the air filter 8. Remove the 2 screws (A) and the cover for the 1. Remove the cylinder cover. heated handle (B).

  • Page 69: To Repair A Damaged Thread

    10. Disconnect the wires and pull out the wires from the Note: For aluminum threads, use helicoil and metric handle. Be careful when you pull the wire through screws. Refer to the manufacturer’s manual for more the handle. information. 1. Use the applicable drill bit to make a new hole that removes the damaged threads.

  • Page 70: Troubleshooting

    9 Troubleshooting 9.1 Troubleshooting 3. Measure the resistance between point (B1) and (D1). The resistance for heating element must be You can do the troubleshooting procedure with most 0,8-1,0 Ω. components attached to the product. Tools necessary for the troubleshooting procedure is: 4.

  • Page 71: Troubleshooting Diagram

    9.7 Troubleshooting diagram Starter rope Perform “Cleaning and inspec- Defect Change part or entire tion” of starter housing does not retract starter if needed. starter housing (see separate instr.) Sticking starter Change part or entire Defect starter housing housing starter if needed. Check air gap between Start rope stuck Change part if needed.

  • Page 72: Engine Running Issue

    Does the Crankcase gaskets engine Crankcase start ? Issue still remains? Perform a visual inspection of interface between Contact your Husqvarna carburettor and intake rubber for leakage. Local Sales Company for advice. 72 - Troubleshooting 722 - 003 - 26.03.2019...

  • Page 73: Engine Running Issue

    Check cables and connectors for wear. Product OK Check torque on ignition coil screws. Check the ground wire. Issue still remains? Contact your Husqvarna Local Sales Company for advice Leakage Check function of decompression valve (if equipped). Check mounting/interface intake rubber and carburettor.

  • Page 74: Ignition System Diagnostic Flow Chart

    9.10 Ignition System Diagnostic Flow Chart Perform visual inspection of unit. Inspect spark plug wire, boot connections. Repair/replace any problem items Install new, properly gapped, manufacturer specified spark plug. Stop switch must be in run position. Perform Spark Test (See separate instructions). End Test Is a strong Does engine...
  • Page 75 722 - 003 - 26.03.2019 Troubleshooting - 75...
  • Page 76 115 99 39-26 2019-03-28...

This manual is also suitable for:

550 xp mark ii545g mark ii550 xp g mark ii

Table of Contents