Husqvarna 545 Chainsaw Manual

The Husqvarna 545 is a professional-grade chainsaw featuring X-Torq engine technology for reduced emissions and fuel consumption, Smart Start for easy starting, Air Injection centrifugal air cleaning system, LowVib anti-vibration system, combined choke/stop control, inertia-activated chain brake, and quick-release air filter. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: X-Torq engine, guide bar, cutting chain, chain brake, throttle trigger, front and rear handles, air filter cover, fuel tank, oil tank.

Assembly & Preparation

Unpack and inspect all parts. Ensure you have proper protective equipment.

1. Attach guide bar and chain: Place bar on studs, fit chain around bar and sprocket, adjust tension.
2. Fill fuel tank: Use Husqvarna 2-stroke engine oil mixed with unleaded gasoline (50:1 ratio).
3. Fill chain oil tank: Use Husqvarna chain oil or equivalent.
4. Check chain brake: Ensure it moves freely and engages properly.

WARNING! Always wear protective gear: helmet, goggles, gloves, hearing protection, chainsaw chaps, and steel-toe boots.

First-Time Operation

Perform pre-start checks before first use.

1. Check chain tension: Chain should be snug against bar but pull freely.
2. Check chain sharpness: Ensure cutting teeth are sharp and depth gauges properly set.
3. Start the saw: Place on flat ground, engage chain brake, set choke, pull starter cord until engine fires.
4. Warm up: Allow engine to idle for 30-60 seconds before cutting.

CAUTION! Never start the chainsaw indoors or in poorly ventilated areas due to carbon monoxide risk.

Specifications

• Engine Displacement: 50.1 cc
• Power Output: 3.2 hp (2.4 kW)
• Fuel Capacity: 0.95 US pints (0.45 liters)
• Oil Capacity: 0.63 US pints (0.3 liters)
• Recommended Bar Length: 13" to 20" (33 cm to 50 cm)
• Weight (without bar/chain): 11.7 lbs (5.3 kg)
• Sound Power Level: 112 dB(A)
• Vibration Levels: Front handle 3.5 m/s², Rear handle 4.5 m/s²
• Ignition System: Electronic, 14,000 RPM max
• Chain Pitch: 3/8" or 0.325"

Controls and Functions

Main controls located on top and sides of saw body.

Right Side: Throttle trigger, throttle trigger lockout, front handle. Left Side: Chain brake/hand guard, rear handle, choke/stop control, primer bulb (if equipped). Top: On/off switch, decompression valve, air filter cover, fuel cap, oil cap.

Chain Brake: Manual activation via hand guard; automatic inertia activation. Throttle Lockout: Must be pressed before throttle trigger operates. Choke/Stop Control: Three positions - Run, Choke, Stop. Decompression Valve: Reduces cylinder pressure for easier starting.

Chain & Bar Setup

Proper chain installation and tensioning is critical for safe operation.

1. Loosen bar nuts with combination wrench.
2. Place bar on studs, ensuring tensioning pin engages in bar hole.
3. Fit chain over sprocket and around bar with cutting teeth facing forward.
4. Tighten bar nuts finger-tight, then adjust tension with side-mounted tensioner.
5. Final tighten bar nuts while lifting bar tip upward.

Tip: Always check chain tension when saw is cold. Chain stretches when warm.

Operating Procedures

Follow proper techniques for safe and efficient cutting.

1. Starting: Engage chain brake, set choke, pull starter cord until engine fires, then move to run position.
2. Cutting: Use full throttle when cutting; let chain do the work without forcing.
3. Kickback Prevention: Keep saw body close to your body; never cut with bar tip.
4. Refueling: Stop engine completely and allow to cool before refueling.
5. Transport: Always engage chain brake when carrying saw.
6. Storage: Empty fuel tank for long-term storage; clean entire saw.

WARNING! Never operate chainsaw above shoulder height or with one hand. Always maintain secure footing.

Safety Features

Chain Brake: Stops chain within milliseconds if kickback occurs. Throttle Lockout: Prevents accidental throttle engagement. Right-Hand Guard: Protects hand from broken chain. Vibration Dampening: Reduces operator fatigue. Exhaust Direction: Channels exhaust away from operator.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and longevity.

Daily: Clean air filter, check chain tension and sharpness, clean saw body. Weekly: Clean cooling fins, check spark plug, clean fuel filter. Monthly: Check all nuts and bolts for tightness, clean chain brake mechanism, check anti-vibration elements. Seasonally: Replace spark plug, clean carburetor air intake, check fuel lines.

CAUTION! Always disconnect spark plug wire before performing maintenance. Use only Husqvarna recommended parts and lubricants.

Regulatory Information

EPA and CARB certified for emissions. Meets ANSI B175.1 safety standards. EU noise emission 2000/14/EC. Contains components that may be hazardous if disposed improperly. For technical support, visit www.husqvarna.com or contact 1-800-487-5952. Serial number located on crankcase. Always record serial number for warranty claims.

Troubleshooting

Reset: For electronic ignition issues, disconnect spark plug wire for 30 seconds to reset system.

Service: 1-800-487-5952; www.husqvarna.com