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Husqvarna 545RXT AT User Manual

Husqvarna 545RXT AT
80 pages
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Workshop manual
English
545RXT AT, 545FX AT, 545FXT AT,
545FX, 545FXT, 545RX, 545RXT

Table of Contents

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Husqvarna 545RXT AT Specifications

General IconGeneral
Engine Displacement45.7 cm³
Weight8.9 kg
Sound Power Level, Guaranteed (LWA)117 dB(A)
Engine Type2-stroke
Fuel Tank Volume0.9 l

Summary

Introduction and Safety Instructions

General Information

Overview of the manual's purpose and content.

Revisions

Information on product changes and manual updates.

Target Group

Identifies the intended audience for the manual.

Safety Instructions

Crucial warnings and precautions for safe operation and maintenance.

Manual Structure

Explains how to navigate and use the manual's structure.

Numbering System

Details the numbering system for components and figures.

Required Tools

Lists special tools and emphasizes using original parts.

Product Symbols

Explains warning symbols and their meanings for user safety.

Technical Data

Engine Displacement

Engine displacement in cm³ and cubic inches.

Cylinder Bore

Cylinder bore diameter in mm and inches.

Stroke Length

Engine stroke length in mm and inches.

Max Output and Speed

Maximum engine output in kW/hp and RPM.

Compression Ratio

Engine compression ratio.

Spark Plug Specifications

Specified spark plug type and electrode gap.

Ignition System Details

Ignition system manufacturer and air gap measurement.

Ignition Timing

Ignition timing at max output and idle.

Air Filter Type

Type of air filter used.

Carburetor Type

Carburetor type.

Max Speed and Idle Speed

Maximum engine speed and idle speed in RPM.

Clutch and Gear Specifications

Clutch diameter, engage speed, gear angle, and bevel ratio.

Shaft and Axle Dimensions

Diameter of the drive shaft and drive axle.

Product Weight and Fuel Capacity

Product weight in kg/lbs and fuel tank capacity.

Service Tools

Wrenches and Testers

T-handle wrenches, spark plug tester, and pressure vacuum tester.

Ignition and Metering Tools

Spacer, tongs, and metering lever height gauge.

Clutch and Flywheel Tools

Tools for clutch drum removal and flywheel removal.

Cleaning and Lubrication Supplies

Detergent and greases for maintenance.

Seal and Bearing Tools

Mandrels and tools for fitting radial sealing.

Testing and Fixturing Equipment

Pressure tester, mounting fixture, and crank stop.

Ignition Checker

Tool for spark strength check.

Service Data

Key to Diagrams

Explains symbols for lubrication and torque values.

Handle System

Stop Switch Dismantling

Steps to remove the stop switch and disconnect cables.

Stop Switch Cleaning and Inspection

How to clean and inspect the stop switch.

Stop Switch Assembling

Steps to reconnect cables and fit the stop switch.

Finger Throttle Dismantling

Procedures to remove the finger throttle and its components.

Thumb Throttle Dismantling

Steps for removing the thumb throttle and its parts.

Finger Throttle Assembling

Instructions for reassembling the finger throttle.

Thumb Throttle Assembling

Steps to reassemble the thumb throttle and connect cables.

Handle Heating Element Replacement

Procedure for replacing handle heating elements.

Muffler

Muffler Dismantling

Steps to remove the muffler and heat protector.

Muffler Cleaning and Inspection

How to clean and inspect the muffler.

Muffler Assembling

Steps to install the muffler and tighten screws.

Starter

Starter Dismantling

Steps to remove the starter components.

Starter Cleaning and Inspection

How to clean and inspect starter parts.

Starter Assembling

Instructions for reassembling the starter.

Ignition System

Checking the Ignition Spark

How to check for spark and inspect the spark plug.

No Spark: Stop Switch Check

Troubleshooting steps for no spark related to the stop switch.

No Spark: Cable and Connection Check

Further troubleshooting for no spark, checking cables and connections.

No Spark: Air Gap Adjustment

Troubleshooting steps for no spark, adjusting air gap.

Ignition Module Dismantling

Steps to remove the ignition module.

Flywheel Dismantling

Procedure for removing the flywheel.

Drive Dogs Replacement

Procedure for replacing drive dogs.

Generator Dismantling

Steps to remove the generator.

Flywheel and Ignition Module Assembly

Steps to reassemble flywheel and ignition module.

Ignition Module Assembly

Procedure for installing the ignition module.

Carburetor

Carburetor Description

Overview of the carburetor's function and design principles.

Carburetor Design

Details the five sub-systems of the carburetor.

Carburetor Function Modes

Explains carburetor operation in different engine modes.

Carburetor Removal from Engine

Step-by-step guide to remove the carburetor.

Carburetor Dismantling

Steps to dismantle the carburetor's metering diaphragm and spiral support.

Carburetor Assembling

Instructions for assembling carburetor components.

Carburetor Assembly on Engine

Steps to install the carburetor back onto the engine.

Post AutoTune Replacement

Notes on post-replacement procedures for the AutoTune unit.

Engine Adjustment with AutoTune

Procedure for adjusting the engine with the AutoTune system.

Fuel System

Air Filter Dismantling

Steps to remove the air filter and its cover.

Air Filter Cleaning and Inspection

How to clean and inspect air filters.

Tank Venting Procedures

Explanation of tank venting and testing procedures.

Fuel Cap Cleaning

Steps to clean the fuel cap and its components.

Air Purge and Fuel Filter Replacement

Procedure for replacing the air purge and fuel filter.

Centrifugal Clutch

Clutch Dismantling

Steps to access and remove the centrifugal clutch.

Clutch Assembly Dismantling

Procedure for dismantling the clutch assembly.

Clutch Shoes and Springs Dismantling

Steps to remove clutch shoes and springs.

Clutch Component Cleaning and Inspection

How to clean and inspect clutch components.

Clutch Shoes and Springs Assembling

Instructions for reassembling clutch shoes and springs.

Clutch Assembly Assembling

Procedure for reassembling the clutch assembly.

Clutch Drum

Clutch Drum Dismantling

Steps to dismantle the clutch drum and bearing.

Clutch Drum Inspection

How to inspect the clutch drum for wear.

Clutch Drum Assembling

Instructions for assembling the clutch drum.

Gear Head

12.4 Dismantling

Steps to dismantle the gear head.

Gear Head Assembling

Instructions for assembling the gear head.

Cylinder and Piston

Cylinder and Piston Dismantling

Steps to dismantle the cylinder and piston components.

Cylinder and Piston Cleaning and Inspection

How to clean and inspect cylinder and piston parts.

Cylinder Pressure Testing

Procedure for pressure testing the cylinder.

Cylinder and Piston Assembling

Instructions for assembling the cylinder and piston.

Insufficient Lubrication Analysis

Analysis and actions for insufficient lubrication of the piston.

Carbon Deposit Piston Damage Analysis

Analysis of piston damage from carbon deposits.

High Engine Speed Piston Damage Analysis

Analysis of piston damage from high engine speed.

Piston Ring Breakage Analysis

Analysis of piston ring breakage causes.

Loose Piston Ring Guide Pin Analysis

Analysis of damage from a loose piston ring guide pin.

Gudgeon Pin Circlip Damage Analysis

Analysis of damage from gudgeon pin circlips.

Bearing Failure Analysis

Analysis of bearing failure causes.

Foreign Object Damage Analysis

Analysis of damage caused by foreign objects in the engine.

Service Tips for Cylinder and Piston

General service tips for cylinder and piston issues.

Wear Tolerances

Specifications for cylinder bore, ring gap, groove, and play.

Crankshaft and Crankcase

Crankcase and Crankshaft Dismantling

Steps to dismantle the crankcase and crankshaft.

Crankshaft and Crankcase Inspection

How to inspect the crankshaft and its components.

Crankshaft and Crankcase Assembling

Instructions for assembling the crankshaft and crankcase.

Troubleshooting

Starter Rope Issues

Troubleshooting steps for a non-retracting or stuck starter rope.

No Rope Resistance

Diagnosing issues with no resistance when pulling the rope.

Choke/Stop Switch Activation Issues

Troubleshooting issues with activating choke or stop switch.

Engine Running Issues

Diagnostic flow for engine running problems.

Ignition System Diagnostic Flow Chart

Flowchart for diagnosing ignition system problems.

Spark Test Procedure

Procedure for testing the spark from the ignition system.

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