How to upgrade Husqvarna 455 Rancher for more power (Husqvarna 460 Rancher top end swap walkthrough)

Hey everyone!
In this video, I show a step-by-step how-to on repairing an overheated Husqvarna 455 Rancher with the OEM piston and cylinder originally designed for a Husqvarna 460 Rancher.
This is a direct bolt on replacement that with a little bit of time, a few common tools, and this video, will upgrade your Rancher 455 from 55.5cc to a 60.3cc.
This is a great upgrade when it's time to repair or freshen up the old trusty Husky 455.
Thanks for watching!
-Dave

[@donyboy73]

nice job Dave!

[@DavesSmallEngines]

Thanks buddy!!!

[@Sensei948]

@@DavesSmallEngines COMPRESION ?

[@jeffreyhershey5754]

@@DavesSmallEngines I bought one of those brand new a few years ago and I couldn't stand it absolutely hated it underpowered gutless wonder and over weight for the size vs weight ratio I sold it about 6mos later All I run now for saws is big jonsered and Stihl I really love the old 2077 _2083 jonsered saws moreso than the husky

[@paulrowe6132]

@@jeffreyhershey5754365

[@jeffreyhershey5754]

@@paulrowe6132 I'll stick with my 77and83 cc saws and bigger those small ones don't do it for me I've got a 372 xp and it's so so nothing like my 2083 turbo jonsered tho that saw is a Boss it just plays with a 36"bar you'd think it was a 372 with a 20" bar

[@craigjones1115]

I enjoyed watching the rebuild. Nice job. Thanks for the video.

[@blairguinea6811]

Nice diagnostic Sir and top build, just love that tidy clean work space too, such a difference !

[@davidfrench195]

Just did the exact repair due to stripped decompression valve worked great Thanks Dave

[@DavesSmallEngines]

That’s great!!! Cheers!

[@raynaldgodin3314]

Well done and well explain, very easy to follow. Thanks Dave!!!!

[@DavesSmallEngines]

That’s Raynald!!!

[@shermankearns200]

Dave you are fantastic. You go through so much effort to help others. No good deeds go unpunished an American saying for the people who are good.

[@DavesSmallEngines]

Thanks Sherman!

[@robertdouglas3456]

Great job Dave! I always pour the old fuel in a pan to make sure it is not contaminated,then I reuse it if it is good! 🤩🤩

[@jcims]

This is the perfect video for me man. My 455R has no power and I just realized its been a couple of years since I even thought about hitting the decompression button. My saw is ~14 years old and hasn't really needed anything, time for a little refresh!

[@803fab2]

Just added a modded muffler to my 455 an it really woke it up no more bog when you are deep in the wood going to add this mod to the things to do great video 👍

[@ej7431]

Great video...Thanks. Learned a great deal, especially upgrading to a 460 later.

[@DavesSmallEngines]

Awesome!

[@kenk3102]

..glad you are back Dave....and thanks for another great DIY video... :)

[@DavesSmallEngines]

Hey Ken! Thanks for the kind words! Cheers!

[@ryanbruner8928]

Dave,great video,thanks! The last time I had to replace a top end,I went with a bigger one as well.

[@DavesSmallEngines]

Hey Ryan! Thanks for the comments! What did you replace?

[@ryanbruner8928]

@@DavesSmallEngines I replaced the top end on an 021,and now it's an 021/23,or something like that? I went from the original 40mm cyl,piston to 42mm If I remember right? ;)

[@nashguy207]

Good to see posting again. I was wondering where you had been!

[@DavesSmallEngines]

Hey Nash! Thanks for being here! Cheers!!!

[@dujeamizic3588]

Nice job Dave!

[@DavesSmallEngines]

Thank you!

[@tedneitzel]

I did the same with my 455 but unfortunately had to go with Hyway big bore but I can still tell a difference in power thank goodness! Got about 12 cord of wood on it now and all good!!

[@rogermcdonald1607]

Its been awhile Dave. Good to see you do another video. Nice repair sir and you have a good used cylinder for another project. It always makes you think when you find loose bolts. You immediately think, someone's been in here and what else am i going to find. Great job Dave as usual!👍🇨🇦🇺🇸Roger

[@DavesSmallEngines]

Thanks Roger!!!

[@koonelos]

Great tutorial, thank you for sharing this excellent video!

[@DavesSmallEngines]

You’re very welcome!

[@henrymurawskibigdogrepair]

Nice work Dave

[@DavesSmallEngines]

Thanks Henry!

[@codyallen1937]

I'm gonna get ready to do the same thing to my 455 rancher then put a 24 inch bar on it thanks for the video !

[@DavesSmallEngines]

Awesome. Let me know how it does with that 24” bar!

[@olefugle]

Great video and nice that you are back. I almost started to worry if you had sunk with that homemade boat. Greetings from Norway🇳🇴

[@DavesSmallEngines]

No way! The boat is awesome!!! Thank you for the kind words

[@stellarproductions8888]

Dave, I am so happy that you have returned! You always put a smile on my face, because you are a wonderful person, and a great chainsaw mechanic. You did an awesome job restoring this saw, it was really fun watching you do it, that piston looked like it was torched! So I'd say overheating is an understatement. Soon it will be cold enough, I will get to see you wear your beanie hat again, and then the universe will be back in balance once again woohoo!

[@DavesSmallEngines]

Hey Stellar! Glad to see you in the comments!!! I’ll be sure to have the beanie on… but I’m in the market for a gas heater!!!

[@stellarproductions8888]

@@DavesSmallEngines Funny cause I just bought the Dreo 24" floor standing electric heater. Even though it's not gas, with 1500 watts of power, it should make a difference in that small garage of yours. And yes to the hat, it's your signature look that I like. And yes, I want to leave you many more comments. So more vids you make, more comments you get. Thanks buddy!

[@GeirAndersenRepairs]

I've been wondering when you'd upload again, and I was happy it happened this afternoon (Norwegian time). Life has a tendency to happen, and there's not much we can do about it, but live it to the max. Stay safe Sir!

[@DavesSmallEngines]

Thanks Andersen for the kind words! It’s very true.

[@trimbaker1893]

Nice pace of work. Not an angry man with a wrench and hammer... I really like my 460. I run a 28" bar with a full chisel skip tooth chain. My saw has cut a mountain of wood. I gave it new ignition and carb, it runs like new. I think it may be a 2010 model. Nice job. George.

[@DavesSmallEngines]

Thanks for the kind words George!

[@markmacdonald6452]

Nice video. I would have used mix oil rather than WD, and probably some case sealant if some kind to prevent an air leak at the base. Expensive new OEM cylinder.

[@DavesSmallEngines]

I've now got an oil squirt can full of Stihl oil.

[@AppalachianWrench]

These clamshell saws don’t really need case sealant with the rubber style bottom end split-line seals.

[@Marty1959]

Well done dave

[@DavesSmallEngines]

Thanks Martin!!!

[@m998hmmwv7]

Very good video. Thanks

[@DavesSmallEngines]

You’re welcome!

[@gasperajdnik5627]

Well done mate 👍🤝

[@DavesSmallEngines]

Thanks for the visit!

[@anthonywashington9569]

Great video

[@brandonbowman4707]

Great job

[@DavesSmallEngines]

Thanks!!!

[@seanmcgillicuddy956]

Welcome back .. More Power .. :)

[@DavesSmallEngines]

Hey Sean! Thanks!!!

[@2THPWR]

Thumbnail! So good.

[@DavesSmallEngines]

MORE POWER

[@larslindthomsen7370]

Hey, David. It's been a long time since the last video. Nice to see you again 👍. Really good teaching video. Lars from Denmark. PS Google Translate.

[@DavesSmallEngines]

Hi Lars! Thanks for the kind words. I’ll keep making more!

[@NoPeoblem389X]

FYI in the future to get a more accurate compression test hold your throttle wide open this allows as much air intake as possible. This really makes a difference when running a wet test. Have fun

[@DavesSmallEngines]

Thanks Raymond!

[@queenstownkid]

thanks dave

[@DavesSmallEngines]

You’re welcome!

[@vetterfellow]

sensei DonnyBoy73 taught you well Grasshopper !!!! 👍 LOL. Dave She purrs like a Kitten !!!. Nice work. Good Show 👌..

[@DavesSmallEngines]

Thanks Vetter!!!

[@robertmailhos8159]

Hopefully the upgrade is cheaper than buying a new one be safe out there Young Man 😎

[@DavesSmallEngines]

Far cheaper. The top end OEM kit was around $250 and the saw itself is $749!

[@robertmailhos8159]

@@DavesSmallEngines the rebuild kit is almost $500 cheaper than the saw

[@garrettstevensen2467]

The most expensive 460 Rancher top end I could find, was: $80 here in the US (California). The saw is about $700 brand new where I'm at. I got the saw for free, since it had gas ran through it.

[@Bungi81]

Hey Dave. Great Job and nice saw 👍👍 Waited for a new vid 🤣🤣 One of my next projects is a blown up 560XPG. I hope that I can reuse the cylinder and put a new Meteor piston into the engine... OEM cylinder and piston is more than 400€ over here...🙈 Greetings from germany, Stefan

[@DavesSmallEngines]

Hey Stefan!!! Good to hear from you. Let me know how it goes!

[@Bungi81]

@@DavesSmallEngines I´ll make a vid about the repair 😉

[@user-nx8vp5sy5d]

My 2nd saw saw was a 455, crap saw lasted 5 yrs. stilh 250 (a not so good saw) that’s almost 30yrs old is still going. Stihl 362 was my 3rd saw great specks but a rubbish saw, stihl 261 amazing saw

[@cogentdynamics]

No gaskets or sealants for the case and carb? Very helpful video, thanks.

[@dominicgorno7158]

Great video. Can you list the part numbers.

[@clinte9897]

Great video, what would have been acceptable range of compression on the 455? So when mine falls below it I can jump on this. Thank you

[@HOMURO]

Congratulations on the video. please tell me what the oil/petrol ratio is and if you have run in the engine and how?

[@HondroGonzalez-zv5zv]

Y hellz yea.awesome

[@Lonewolve1988]

How do break in a new saw or as in this case....cylinder / piston? Also how much more horsepower was the upgrade, would porting and a muffler upgrade add more horsepower also?

[@alanreynolds2125]

Good job Dave only thing I would say wd40 is not really a lubricant why not us two stroke oil after all that’s what it will run on! Cheers

[@DavesSmallEngines]

Hey Alan! Good point. I’ll make an adjustment! Cheers!!!

[@blueridgemountainprepper2166]

Question, will a 465 rancher jug and piston swap onto the 455? I have a 455 I'm wanting to bump up as much as possible. I use to have a 365 special, I loved that 65cc saw, regretted selling it

[@robertingoldsby1638]

DonyBoy would have checked for leaking crankcase seals before disassemble.

[@ethum2]

I have the same chainsaw but i have a small question. Started the chainsaw after a month of non-use and then i start it up but after like 10-15 seconds if i don't accelerate the engine it automatically shuts down. I need to constantly accelerate the engine to keep the chainsaw working if not it will simply shutdown. Any tips?

[@jimgroulx3956]

Hey Dave Perfect timing. I had been wondering if this exact upgrade was possible and voila here it is. Thanks very much for it. A couple of questions though 1..... is it not necessary to change the base and crank seals? 2....where would you suggest ordering a kit like that from? Thanks again and enjoy your day from the land of the sleeping giant!

[@DavesSmallEngines]

Hey Jim! It is not necessary… recommended sure…. But not necessary depending on the condition of the seals. This saw was lightly used. One trick you can do is to flip the base gaskets over so the bottom side is on the top. I’m in Canada and I ordered it from Sawparts.ca using a 25% coupon. I would 100% recommend going with an OEM kit. Let me know how it goes if you have any questions!

[@_JamesBrown]

I have a 450 that someone ran straight gas through. What's the largest top end I can swap on that saw? Thanks!

[@jeffdenney4148]

Where did you get the kit I have a 455 rancher good video thanks

[@lexiusnez6513]

Dave what's the OME number for the 460 cylinder kit?

[@William_Charles_Baker]

Very nice video! I just, today, did this upgrade to a 15-year old 455 that has cut over 125 cords of red and white oak. When I'm bucking trunk I run a 24" bar with a full skip chain. Although tired with only 106 PSI of compression it still ran great, just lacking power. The piston was in good shape and the ring wasn't stuck. Now the compression is back to 150 PSI. So my question is this, did you have to make any carburetor (tuning) adjustments after the upgrade?

[@DavesSmallEngines]

Yes, I did. I let it have some more fuel. It will be fine without the adjustment but everyone's mileage may vary depending on location, fuel, temperature etc.

[@dathvader82]

I have the 455 as well. Do you think just upgrading the muffler would help with power. I put a 24" bar on. It said it could handle it, but honestly with a full house chain on her, the chain grips more than the power to pull it through the log.

[@dathvader82]

Or do you think doing the muffler along with a skip tooth? Or just a skip tooth? Just a muffler?

[@lowhook1]

Do you have a link for the 460 bore kit? Thinking of beefing up my 455 now looks like fun.

[@jamesjoste8655]

I’m probably mistaken but every cylinder I found for the 455 and 460 was 47 mm both of them where can you find a bigger piston and cylinder

[@mriguy3202]

Does the overheating happen because the saw was clogged with sawdust and oil, and not cleaned out? It would be interesting to compare the costs and benefits of the choices made on this repair...you can buy a new saw like this for about $500 and a used one for $300. If the owner had opted to just replace the ring, he might have had a saw that ran as good as new.

[@dimitrijejovic2000]

What Is the minimum compression for Husqvarna 460 rancher.

[@eddierose8059]

Which 460 kit did you use? There are many models of 460. Does it matter? Are they all the same? I'm interested in doing this mod when the time comes. Thanks!

[@MrSprintcat]

Hey Dave new subscriber here . Thank you for the video,i have a few questions for you . I had my exhaust off yesterday befor watching this video, the gasket was not where you put the gasket, it was aluminum shield gasket then the exhaust can . You can even see the impression in the aluminum where it hits the port, this saw has never been apart, and one more question did you remove the little tamper collar's from the carburetor? I did and installed the needle back in with just the springs, just wondering if you had done it this way before? Thanks again😊

[@shermankearns200]

Sometimes a small piece of porcelain from the spark plug 🔌 can pin 📌 the rings 💍.

[@DavesSmallEngines]

Good to know!

[@cbnx82703]

You should of done a post repair compression test ...!

[@DavesSmallEngines]

I should have! Maybe once it breaks in.

[@willbrennan3840]

Could the decomp valve have played a role on the loss of compression

[@DavesSmallEngines]

A failed decomp valve will play a role in loss of compression, yes.

[@ocsplc]

Dave: I own a 460 Rancher. It’s my only “non-pro” saw, but my question is why bother with the head upgrade when you could just take the baffle out of the OEM muffler and add another small air port in the muffler? Shouldn’t that equate to about the same Hp increase?

[@DavesSmallEngines]

I’m not sure - you would have to dyno test them for the results. Good question!

[@btadlysexton4187]

Hey, I just thought of something….. what about cylinder/piston OEM (or aftermarket) for disconnected 465 Rancher into 455 Rancher?!?!? Would it still fit same way as that 460 kits went in? I’m having a thought of finding me used 455 and buy 465 parts to do it. Lol.

[@DavesSmallEngines]

I’m not sure those model numbers would line up.

[@williamlockhart5031]

Hi Dave! What did you mean by the crankshaft being at the right tvc?

[@DavesSmallEngines]

Hey William - I think I mean TDC - top dead centre. The top of the travel for the piston.

[@eduardo_k]

So what do you think caused the burnt piston, lean mixture or a bad seal?

[@DavesSmallEngines]

Probably a dull chain and over revving, or straight gas / not enough oil, if I had to guess.

[@ThaiXLe]

Will this work on a 55 Rancher?

[@adnacraigo6590]

Are both of these saws US made or Swedish made? I didn't know that those cylinder jugs, etc were interchangable.

[@DavesSmallEngines]

Good question, I’m not sure!

[@ericoverdorff8880]

Wd40 isn't actually a lubricant, it's a solvent. You should use 2 stroke lube or assembly grease when assembling.

[@DavesSmallEngines]

I have switched to using a squirt bottle of 2 stroke oil!

[@jeffdenney4148]

What’s the part number I want to make my455 into a 460

[@drivingonice]

I tried for 4 hours last night to get my new piston into the cylinder. All these videos make it look easy. I don't know what I am doing wrong but it is not working.

[@TruSpec_Gaming]

So when you swap does the air intake or exhaust not need upgraded.

[@DavesSmallEngines]

I don’t think so!

[@chriseller757]

Yea your supposed to hold the throttle wide open when you do a comp test there bud.

[@calvinrowe4263]

Could I do this on a 450 rancher?

[@DavesSmallEngines]

I’m not sure. I think it’s just 455 -> 460

[@jeffdenney4148]

How big is the stock piston

[@12what34the]

The 455 should be 55.5 cc (3.38 cubic inch). The 460 should be 60.3 cc (3.68 cubic inches). Husqvarna saw names usually indicate the cubic centimeter displacement (or close to it)

[@lexiusnez9034]

I have an 2007 455 Rancher and I'm having a problem with leaking fuel. Was wondering if you have information on where I could get some correct size fuel lines and also where you got the upgraded parts. Thanks

[@emilsalman7263]

My 455 rancher was leaking fuel from where the purge fuel line (tube) entered the fuel tank. I pulled the tube out and took to napa auto parts and matched it. It was less than the cost of buying the husqvarna part, I ended up buying a new spark plug for it and still costed less than half the price.

[@DavesSmallEngines]

Sounds like Napa it is! If not, I do all of my ordering online from various parts providers.

[@keithbell8690]

@@DavesSmallEngines Where do you buy your fuel tank bushings? I have a 455 rancher that I just replaced the fuel line

[@purebrawn5208]

From the comments it looks like you have been away... never noticed

[@DavesSmallEngines]

I’m pinning this comment

[@stellarproductions8888]

@@DavesSmallEngines The fact 3-months went by and they never noticed you were gone, just shows they never were a true subscriber, and most certainly not your friend! I however noticed something was up at the 3-week mark, by 4-weeks, I began asking Don where you were.

[@keithclark486]

Where are you located NC ?

[@DavesSmallEngines]

Ontario, Canada!

[@MartyyyR]

Did you just do a compression Test with a pushed decompression Valve ?? Dude i watched that scene several times and i think it is pushed. Of course the Piston Ring is stuck, so it needs a repair anyways... As alan said : WD40 is better for cleaning than for lubing. Btw, nice to see that you are back.

[@DavesSmallEngines]

Marty! Wow, I think you're right. OOPS! I had done one previously and had a low result (I recall around 75) and the saw wouldn't fire so it was certainly a ring issue. I'll be more careful next time, and I've transitioned to using 2 stroke oil instead of WD40. Thanks for the comments!

[@rmanbike]

Why not just bore the old cylinder head and get a new 460 piston set?

[@jackylsmith8138]

There is a lining which is very hard put on the cylinder, if you bore it you will have to replace the finish. You can do a quick hone to restore cross hatching. That original cylinder most likely could have been re used. With a new piston and ring.

[@garyhuizen8565]

Nice video, what would that cost to have done?

[@DavesSmallEngines]

Depends! I'm cheap... but whatever the OEM kit costs which I believe was 200-250$ Canadian and then whatever an hours labour would cost.

[@ozarkprepper1718]

Can a guy put a 450 cylinder kit on a 445?

[@DavesSmallEngines]

I’m not sure! I think this only works with 455/460

[@ozarkprepper1718]

@@DavesSmallEngines i found out that they are the same except for cylinder bore. 445 is 42mm. 450 is 44mm. I rebuilt my 445. Turns out. It was a 450 already! Someone put the wrong cover on it brand new.

[@beekone28]

Sorry i have to help you out of your dream, but you don't upgraded the 455 with the 460 cylinderkit. they share the same cylinder and piston. The 460 has a larger stroke crankshaft witch makes the difference in cc's. But nice job for your friend. everyting is fresh to run a lot of hours again! When you want to upgrade the power you can change the crank for a 460 one. or better, just open up the inlet 10 or 15 degrees and it will run much faster.

[@DavesSmallEngines]

Hey! I believe the revised Rancher 455 is a 47mm piston vs 49 for the 460!

[@beekone28]

hi Dave, i think you helped me out of my dream. i looked back the article what i read in the past on arboristsite. they speak about a 32 and 34 mm stroke. but when i do the math this can not make the exact difference betweet 55.5 and 60.3 cc. a bore from 47 and 49 does! On all places were i look they advert for a cylinder kit what fits on both 455 and 460. It will fit, but will be a downgrade for the 460. so i think you are right. Now i can look for a big bore kit for my 455 rancher. At the moment i got a tuned 47mm kit on it with higher compression, bigger transfers and more intake duration. i already gained 1,5 times faster cutting times, but with a bigger bore it becomes stronger. you helped me on a new project. thanks!

[@mm88swrt]

To bad my 455 runs like a champ right now, I'd like to juice it up to a 460 lol

[@DavesSmallEngines]

Maybe one day!

[@unknownpresident]

somthing fishe here , o it's shark week It started quickly , too quickly for a rebuilt engine ,

[@DavesSmallEngines]

I was surprised myself... must have been the residual gas in the cylinder!

[@jabbawalkie1726]

do you not use any gasket sealant or a gasket for the top end and bottom end. WTF

[@purebrawn5208]

The thing only started because of all the WD you sprayed in there

[@purebrawn5208]

Man im funny

[@DavesSmallEngines]

Probably true

[@stellarproductions8888]

@@purebrawn5208 Yeah......Funny looking. 🤪

[@Ecksterphono]

Love the video on the upgrade from a 455 to a 460. However when I found out that xtorq is pretty much a Xenoah racing design engine and not much of a chainsaw packing power engine, I was disappointed with Husqvarna. All one is doing when upgrading from a 455 to the 460. Is upgrading from a hot engine to running even a hotter engine. All that wasted heated expanded air that passes through the xtorq passages and the piston port is the wasted energy that should be in the cylinder. After the engine wears it causes a lot of reversion on the downstroke which the EPA love to keep the emissions down and the performance low. Also I've noticed that this reversion also causes the air cleaner to gum up and poor idle performance and a slight puff out sound of the air cleaner on throttle down due to the xtorq action almost like backfire. Lots of piston fouling on these single ringed engines and a high rpm unit which go through chains and constant sharpening. The oiler doesn't even keep up on the chains lubrication needs. Lots of torque bog. My regular 55 Electrolux out performs the 455 and the 460 plus runs way colder with less piston issues and less fuel consumption. These xtorq saws overheat way too much and also go through sparkplugs as well. Also don't get the saw out of the box that comes with the chain supplied with it. The bar is fine but the Husqvarna chain is not good for felling, but good for around the yard fire wood bucking and not for big log bucking. I think I might go with Stihl, because Husqvarna is falling behind. It used to be the other way around.

[@joeshmoe5935]

45:1 fuel. I thought husky was 50:1 at least my weed wacker is. YOU use 45:1 cause you like more oil or cause that is factory? Guess I have to label one more gas can.

[@DavesSmallEngines]

Hey Joe - that’s advice I got from Donyboy73, the small engine doctor. I’m sure it’s a bit safer than 50:1 and will make up for any errors made on mixing. Cheers!

[@aussiehardwood6196]

Put a new ring in it dave

[@DavesSmallEngines]

Certainly could have - my friend wanted more power and the fresh 460 top end!!!

[@EcSsAwS]

Lol. I can tell somebody is a rookie 😆😂😂 Could have left the recoil. Clutch cover and handle all in place

[@Robert_H_Diver]

🤡

[@kenwood197]

repair kit cost more than half of the price of entire chainsaw ....

[@quick281]

Needs an AMSOIL diet!

[@kevywilliams3304]

Omg buy a new saw . Obviously he is to rough on the small thing