Husqvarna 455 Rancher II Workshop Manual
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Husqvarna 455 Rancher II Workshop Manual

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Workshop Manual
455, 455e, 455e TrioBrake
465 Rancher II
English

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Summary of Contents for Husqvarna 455 Rancher II

  • Page 1 Workshop Manual 455, 455e, 455e TrioBrake 465 Rancher II English...

  • Page 3: Table Of Contents

    Safety equipment ..........16 Repair instructions ..........24 Carburetor ............. 35 Troubleshooting ............ 56 Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify the design and appearance of products without prior notice. English –...

  • Page 4: Index

    Index Index Special Instructions 8 Structure 7 Bar bolt Symbols in the Workshop Manual 9 Replacing the bar bolt 55 Symbols on the saw 9 Target group 7 Tools 7 Carburetor 35 Assembly 40 Cleaning and inspection 40 Design 35 Muffler 19 Disassembly 37 Assembling the muffler 19...
  • Page 5 Index Tank unit 45 Venting the fuel tank 45 Technical data 10 The intake system 33 Assembling the intake system 34 Cleaning and inspection 33 Dismantling the intake system 33 Threads 55 Repairing damaged threads 55 Throttle lockout, throttle and spring 22 Assembling the throttle lockout, throttle control and spring 23 Cleaning and inspection 22...

  • Page 6: Introduction And Safety Regulations

    Introduction and safety instructions 2 Introduction and safety regulations Table of contents General ..........................7 Safety ..........................7 Target group ........................7 Changes ..........................7 Tools ...........................7 Structure ..........................7 Numbering ..........................7 General instructions ......................8 Special instructions ......................8 2.10 Symbols on the saw ......................9 2.11 Symbols in the Workshop Manual ..................9 6 –...
  • Page 7 Workshop Manual. unit in order to increase basic understanding. Usage is made apparent in each section. 2.7 Numbering Always use original Husqvarna: • Spare parts Position references to components in the figures are designated A, B, etc.
  • Page 8 Introduction and safety instructions 2.8 General instructions 2.9 Special instructions The workshop where the chain saw is to be re- The fuel used in the chain saw has the following paired must be equipped with safety devices in hazardous properties: accordance with local regulations.
  • Page 9 Introduction and safety instructions 2.10 Symbols on the saw 2.11 Symbols in the Workshop Manual The symbols below are embedded on the chain saw. This symbol warns of personal injury Choke control when the instructions are not followed. Use protective gloves. Fueling Use protective goggles.

  • Page 10: Technical Data

    Technical data 3 Technical data Displacement Cylinder diameter Stroke Max. output/speed cm3/cubic inch Ø mm/Ø inch mm/inch kW/hp/rpm 455 RII: 55.5 / 3.38 47 / 1.85 32 / 1.26 2.6 / 3.5 / 9,000 455e RII: 55.5 / 3.38 47 / 1.85 32 / 1.26 2.6 / 3.5 / 9,000 455e RII TB:...
  • Page 11 Technical data Engage speed Spark plugs Oil pump type 455 RII: 4 100 (+/- 120) NGK BPMR 7A Adjustable 455e RII: 4 100 (+/- 120) NGK BPMR 7A Adjustable 455e RII TB: 4 100 (+/- 120) NGK BPMR 7A Adjustable 465 RII: 4 100 (+/- 120) NGK BPMR 7A...

  • Page 12: Service Tools

    Service tools 4 Service tools 12 – English...
  • Page 13 Service tools Pos Designation Used for Order no. Clutch tool Centrifugal clutch 502 54 16-03 Piston stop Crankshaft lock 504 91 06-05 Hook for fuel filter Lifting out the fuel filter 502 50 83-01 Allen key, 4mm For M5 screws 502 50 18-01 Pressure tester Pressure testing the cylinder...

  • Page 14: Service Data

    Service data 5 Service data 18-25Nm 16mm 12-14Nm 13mm 1,5-2Nm 4mm 1-2Nm 1-2Nm 12-14 Nm 5mm 13-15Nm 4mm 5-6Nm 4mm 1-2Nm 3-4Nm 4mm 11-13Nm 13mm 22-25Nm 13mm 1,5-2,5Nm 4mm 20Nm 1-1,5Nm The numbers by the components to be assembled with screws state the tightening torque in Nm. s = Lubricate using two-stroke oil.
  • Page 15 Service data 3-4Nm 4mm 3-4Nm 4mm 3-4Nm 4mm 1-1,5Nm 4-5Nm 4mm 3-4Nm 4mm 2,5-3,5Nm 4mm 4-5Nm 4mm 1-1,5Nm 2-2,5Nm 4mm 3-4Nm 4mm 2,5-3,5Nm 4mm 3-4Nm 4mm 4-6Nm 4mm English –...

  • Page 16: Safety Equipment

    Safety equipment 6 Safety equipment Table of contents 6.1 Dismantling the chain brake ....................17 6.2 Assembling the chain brake ....................18 6.3 Dismantling the muffler ......................19 6.4 Assembling the muffler .......................19 6.5 Replacing the chain catcher ....................20 6.6 Installing a spike bumper ....................20 6.7 Dismantling the start/stop switch ..................20 6.8 Assembling the start/stop control ..................21 6.9 Resistance test - stop function ...................21...

  • Page 17: Safety Equipment

    Safety equipment 6 Safety equipment 6.1 Dismantling the chain brake Release the brake by moving the hand guard back- wards. Dismantle the clutch cover, chain and bar. Fig 1 Dismantle the hand guard. Carefully tighten the clutch housing in a vice. Re- lease the brake by using the saw's hand guard as a tool.

  • Page 18: Assembling The Chain Brake

    Safety equipment 6.2 Assembling the chain brake Screw the knee joint and the brake band together (see figure 5) with a tightening torque of 1-1.5 Nm. Place the knee joint with the fitted chain brake band in the opening in the clutch cover. The space for the spring in the cover must be lubricated with grease.

  • Page 19: Dismantling The Muffler

    Safety equipment Functional inspection: Do not turn on the motor when carrying out this inspection. Bar length Height 38-51 cm/15-20" 50 cm/20" 53-71 cm/21-28" 70 cm/28" Hold the chain saw over a stable surface. The • distance between the bar and the surface is shown in the table above.

  • Page 20: Replacing The Chain Catcher

    Safety equipment 6.5 Replacing the chain catcher A worn chain catcher must always be replaced with a new one. Always use original spare parts. Release the brake by moving the hand guard backwards. Remove the clutch cover, bar and chain. Remove the chain catcher and replace with a new Fig 12a one.

  • Page 21: Assembling The Start/Stop Control

    Safety equipment 6.8 Assembling the start/stop control Fit the new stop control (A) and tighten screw (B) in place with a torque of 1 Nm. Slide in the stop control in the rubber sleeve C and hook the sleeve on the guide taps. See figure 14. Fit the cables as outlined in Figure 15.

  • Page 22: Dismantling The Throttle Lock, Throttle Control And Spring

    Safety equipment 6.10 Dismantling the throttle lock, throttle control and spring Dismantle the rear handle screws (3) and loosen the handle half. See figure 18. Fig 18 Loosen the throttle lockout from the handle and then dismantle the spring and throttle. See figure 19.

  • Page 23: Assembling The Throttle Lock, Throttle Control And Spring

    Safety equipment 6.11 Assembling the throttle lock, throttle control and spring Attach the spring to the throttle as outlined in figure 21. Ensure correct positioning of the spring by fastening one end to the triangular recess in the throttle. Fig 21 Attach the throttle to the handle.

  • Page 24: Repair Instructions

    Repair Instructions 7 Repair instructions Table of contents Dismantling the starter .....................25 Changing a broken or worn starter cord ................26 Tensioning the return spring .....................26 Replacing a broken return spring ..................27 Assembling the starter unit ....................27 Dismantling the ignition module and flywheel ..............28 Assembling the ignition module and flywheel ..............29 Dismantling the centrifugal clutch ..................30 Assembling the centrifugal clutch ..................31...

  • Page 25: Repair Instructions

    Repair Instructions 7 Repair instructions 7.1 Dismantling the starter Loosen the four screws, which hold the starter against the crankcase and remove the starter. Pull the cord out about 30 cm and lift it into the notch on the outside of the starter pulley. Release the tension in the return spring by letting the starter pulley rotate anti-clockwise.

  • Page 26: Changing A Broken Or Worn Starter Cord

    Repair instructions 7.2 Changing a broken or worn starter cord When the starter cord is worn and must be replaced, the tension in the return spring must be released. Pull out the starter cord about 30 cm and lift it into the notch on the outside of the starter pulley.

  • Page 27: Replacing A Broken Return Spring

    Repair Instructions 7.4 Replacing a broken return spring WARNING! Exercise care to ensure the spring does not fly out and causes personal injury. Wear protective goggles. Loosen the screw at the center of the starter pul- ley and the screws on the cassette. Remove the starter pulley with the cassette and spring.

  • Page 28: Dismantling The Ignition Module And Flywheel

    Repair Instructions 7.6 Dismantling the ignition module and flywheel Remove the cylinder cover and starter. Unsnap the cables from the guide rail as outlined in figure 7. Remove the guide rail. Fig 7 Knock out a few of the pins in the tool if it does not match up with the flywheel.

  • Page 29: Assembling The Ignition Module And Flywheel

    Repair Instructions 7.7 Assembling the ignition module and flywheel Put the ignition module into position. Put the cable through the hole in the crankcase and plug in the connector. Fasten the ignition lead to the attachment on the partition wall. See figure 11. Fig 11 Fit the flywheel onto the crankshaft journal.

  • Page 30: Dismantling The Centrifugal Clutch

    Repair Instructions 7.8 Dismantling the centrifugal clutch Release the brake by moving the hand guard backwards. Remove the cylinder cover, the clutch cover, the chain and the bar. Loosen the spark plug hat and remove the spark plug, and insert the plastic piston stop (504 91 06-05).

  • Page 31: Assembling The Centrifugal Clutch

    Repair Instructions 7.9 Assembling the centrifugal clutch Fit the clutch springs onto the shoes using circlip pliers as outlined in figure 18. Screw in the clutch (anti-clockwise) until it stops. Then tighten the clutch using tool 502 54 16-01 and a suitable socket wrench or combination span- ner.

  • Page 32: Assembling The Oil Pump And Screen

    Repair Instructions 7.11 Assembling the oil pump and screen Lower the oil filter, replace the oil pump as out- lined in figure 20 and tighten the screw. Tightening torque 1.5-2.5 Nm. Fit the chain guide plate. Fit the pump drive wheel, needle bearing, clutch drum and clutch.

  • Page 33: Dismantling The Intake System

    Repair Instructions 7.12 Dismantling the intake system The intake system consists of: • partition wall A • intake manifold B • carburetor flange C • impulse hose D See figure 23. Dismantle the following parts: • cylinder cover • air filter •...

  • Page 34: Assembling The Intake System

    Repair Instructions 7.13 Assembling the intake system Assemble the carburetor flange on the intake bellows. Fit the impulse hose, intake bellows and partition wall on the cylinder. See figure 26. Place a new cylinder pedestal gasket on the cylin- der. See figure 26b. Fit the cylinder.

  • Page 35: Carburetor

    Repair Instructions 7.14 Carburetor WARNING! The fuel used in the chain saw has the following hazardous proper- ties: 1. The fluid and its vapor are toxic. 2. Can cause skin irritation. 3. Is highly flammable. Description The figures accompanying this description do not correspond with the carburetor on the chain saw.
  • Page 36 Repair Instructions Function The carburetor operates differently in the following modes: • Cold start mode • Idling mode • Part throttle mode • Full throttle mode In cold start mode the choke valve H is completely shut. This increases the vacuum in the carburetor and fuel is easier to suck from all the diffuser jets D, E, and F.
  • Page 37 Repair Instructions Dismantling the carburetor Dismantle the cylinder cover and the air filter. Loosen the suction hose A, the return hose B and the fuel hose C. See figure 34. Fig 34 Detach the earth cable from the carburetor by undoing the screw as outlined in figure 35.
  • Page 38 Repair Instructions Undo screws E. Unhook the rubber mountings D on both sides. See Figure 36b. Remove the air filter holder. Fig 36b Note! The lug on the carburetor must be detached from the partition wall before the carburetor can be removed.
  • Page 39 Repair Instructions Dismantle the pump cover H and carefully remove the control diaphragm J and gasket K. Unscrew screw P and remove needle valve M with lever arm Q, shaft L and spring R. Use a needle or similar device and carefully pull up the fuel screen (W).
  • Page 40 Repair Instructions Assembly Cleaning and inspection Observe cleanliness when assembling the car- Clean all units in clean petrol. buretor. The slightest contamination can result in Use compressed air to dry the petrol on the downtime. components. Direct the air through all channels in 1.
  • Page 41 Repair Instructions 5. Assemble needle valve M with lever arm Q, shaft L and spring R, and tighten screw P. (Fit the expansion washer). See figure 40. Fig 40 6. Using a ruler or a similar tool, check that the lever is level with the assembly plane on the cover as outlined in figure 41.
  • Page 42 Repair Instructions Pressure testing the carburetor Pressure testing should be carried out with the car- buretor fully assembled. Testing should always be carried out after the carburetor has been repaired but a test can also be made for troubleshooting before dismantling. Test 1 See figure 43 and check as follows: Connect pressure gage 531 03 06-23 to the carbu-...
  • Page 43 Repair Instructions Fitting on the saw Press the connector together as outlined in figure 44 and press it into place in the holder. Fig 44 Connect the cables to the stop switch. See figure 45. Fig 45 Fit the carburetor and make sure the lug on the carburetor hooks in place on its mounting on the intake system.
  • Page 44 Repair Instructions Place guide pins on the air filter holder in the rubber grommets D. Tighten the screws E. Tightening torque 1.5-2 Nm. See figure 48. Fig 48 Press down the throttle valve shaft (1) and fasten the throttle pressure rod out to its fastening as outlined in figure 49.

  • Page 45: Tank Unit

    Repair Instructions 7.15 Tank unit WARNING! The fuel used in the chain saw has the following hazardous properties: The fluid and its vapor are toxic. Can cause skin irritation. Is highly flammable. 7.16 Aerating the fuel tank The two-way valve has the following properties: •...

  • Page 46: Vibration Damping System

    Repair Instructions 7.17 Vibration damping system Disassembly Release the brake by moving the hand guard backwards. Remove the cylinder cover, the clutch cover, the chain and the bar. Loosen the screws as outlined in Figure 53. Dismantle the hand guard. Fig 53 Press down the throttle valve shaft (1) and remove the throttle pressure rod (2) out of its fastening.

  • Page 47: Replacing The Fuel Filter

    Repair Instructions 7.18 Replacing the fuel filter NOTE! Fluted pliers may not be used with the fuel hose. They can cause material damage resulting in damage to the fuel hose. When replacing the fuel filter, the old fuel filter must be taken out of the tank unit using special tool 502 50 83-01.

  • Page 48: Replacing The Tank Ventilation Valve

    Repair Instructions 7.21 Replacing the tank ventilation valve Pull out the tank ventilation valve with fluted flat nose pliers. See figure 58. Carefully fit the new tank ventilation valve with a suitable sleeve. Fig 58 7.22 Dismantling the piston and cylinder Dismantle: •...
  • Page 49 Repair Instructions Cleaning and inspection of the cylinder Clean all components, and scrape off all gasket remains and soot from the following areas: • The piston crown • The top of the cylinder (inside) • The cylinder exhaust port • The decompression valve channel •...

  • Page 50: Assembling The Piston And Cylinder

    Repair Instructions 7.23 Assembling the piston and cylinder Oil the gudgeon pin bearing with two-stroke oil and insert it into the crank rod. See figure 64. Fit the piston with the arrow facing the exhaust port, slide in the gudgeon pin and fit the circlips. NOTE! Use new circlips.

  • Page 51: Pressure Testing The Cylinder

    Repair Instructions 7.24 Pressure testing the cylinder Dismantle: • cylinder cover • carburetor* • spark plug * See specific instruction. Attach the cover plate (A) 574 71 14-01 and cover plug (B) 578 02 13-01. See figure 66b. Loosen the screws on the muffler and press the cover plate 502 54 11-02 (C) between the muffler and cylinder.

  • Page 52: Dismantling The Crankcase And Crankshaft

    Repair Instructions 7.25 Dismantling the crankcase and crankshaft Dismantle the following: • clutch cover • chain and bar • cylinder cover • starter * • centrifugal clutch * • carburetor* • muffler * • handle system • hand guard • piston and cylinder* * See specific instruction.
  • Page 53 Repair Instructions Cleaning and inspection Clean all parts and scrape off all gasket remains from the contact surfaces on the crankcase halves. Check the following: That the big-end bearing does not have any radial play. Axial play is permitted. See figs. 69 and 70. That the big-end bearing does not have any score marks or Fig 69...
  • Page 54 Repair Instructions Fit the new bearing on the crankshaft using tool 502 50 30-18. See figure 73. NOTE! Take care to prevent any dirt or foreign particles from entering the bearings. Fig 74 Assembling a complete crankshaft Fit the complete crankshaft in the crankcase. See figure 75.

  • Page 55: Replacing The Bar Bolt

    Repair Instructions 7.26 Replacing the bar bolt Replacing a bar bolt with intact crankcase Empty and clean the chain oil tank. Knock in the old bar bolts from the outside so that they end up in the chain oil tank. (The plas- tic surface on the head will break.) Remove the bolts from the oil tank.

  • Page 56: Troubleshooting

    Troubleshooting 8 Troubleshooting Table of contents 8.1 Troubleshooting ........................57 8.2 Troubleshooting techniques....................58 56 – English...
  • Page 57 Troubleshooting 8.1 Troubleshooting The different faults which may occur on the chain saw are divided into four groups. Within each group, the possible operating faults are listed to the left while the probable fault alternatives are listed to the right. The most likely fault is listed first, etc.
  • Page 58 Troubleshooting High speed Acceleration and retardation Does not run Blocked air filter Does not Blocked air filter at full throttle Tank venting clogged accelerate Tank venting clogged Blocked fuel filter The engine Blocked fuel filter Blocked fuel line stops when Blocked fuel line Loose or faulty fuel pipe releasing the...
  • Page 60 • 115 47 67-26 2015W24...

This manual is also suitable for:

455e rancher ii455e rancher ii triobrake465 rancher ii

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