Chainsaw Crankcase Assembly Tool Kit

For those interested in tooling to help improve your saw building experience, you’ve come to the right place!

Please have a look at the information below and email me back if you are interested. Don’t forget the tips and tricks at the end!

Depending on what saws you intend to work on, I can guide you to the particular kit you need.

What does this kit not do?
This kit is not designed for bearing removal from crankcases or crankshafts, splitting crankcases, or installing bearings in a crankcase. All of this can be found on my youtube channel where I explain how I do these type of procedures.

What does this kit do?
This kit is designed for assembly of 2 cycle crankcases. Its sole function is to pull a crank through bearings, at room temperature, with no lateral forces applied to the bearings. This step is by far the most frustrating part of saw assembly (especially for novices…though seasoned veterans find this kit very helpful) and these tools make installation a snap.

Main Crankcase Assembly Tools Kit

Most people are best served with this MAIN KIT.

The current version of this kit of tools is $210, shipped to the lower 48.

Here is the entire kit, comprised of all the component tools required for all chainsaws in the color code chart below.

Your Chainsaw Crankcase Assembly Main Kit Contains:

4 threaded rods. This should cover most of the flywheel and clutch side thread sizes for the relevant saws:
Stihl 026/260, 036/360, 044/440, 066/660,

Husqvarna 346, 262 288, 394, 372 etc etc.

rod 1: 5/8″ flywheel side rod m8x1.0 RH and m10x1.0 RH
rod 2: 3/4″ clutch side M10x1.0LH and M10x1.5LH
rod 3: 3/4″ clutch side M12x1.0LH and M12x1.25LH
rod 4: 3/4″ clutch side M14x1.0LH and m14x1.25 LH

You get 2 sleeves. I REALLY had hoped to only need one sleeve, but because some of the saws have such tight flywheel side seal pockets, a smaller sleeve is indeed necessary. (For example: 044 has a 19mm flywheel side seal pocket, which the small sleeve is designed to fit in…again…its a tad tight.)

You also get 2 nuts and washers, + two threaded rods for a handles.

SPECIALTY RODS and SLEEVES:

For those that work on saws that are beyond the purview of the main kit…

242: I have a special rod for the 242xp (and family). its NOT included in the above kit. because the 242 is a very specific saw and has specificly different thread sizes (m8x1.25RH and 3/8″ UNC LH), it will mean an additional rod. The 242xp rod is an additional $35 to add to the above kit. 10 or so in stock currently

661 / old 266: the old style 61/266 clutch side rod is 1/2″ UNC LH now available and the other end goes to the stihl 661 is m13x1.0 LH … this rod is also not included in the general kit… $35 additional each. 20 in stock
661/ 076 : this is a new rod and has m13x1.0lh for 661 and m12x1.5lh for 076 … 9 in stock

576xp: the husky 576xp family requires an m15x1.25LH rod. $35 additional each, this rod is a single ender, in STOCK

880: It has come to my attention that the stihl 880/084 have a larger than average clutch side bearing and the large sleeve will not fit it. the rods do fit, but the clutch side bearing has too large an ID to have the large sleeve fit over it. So I am making a large sleeve to specifically fit the 880’s. IN stock $40 shipped

076 UPDATE: because the 075/076 have large big end bearings, they will require the 880 sleeve. ALSO, their clutch side has a unique thread which requires the 661/076 rod above… please inquire about this if you need tooling to do 076’s.

SAW SPECIFIC KITS:

I have 660 exclusive/standalone kits available. if you just want to put together a 660, I can send you a 660 specific rod, large sleeve, and nut and washer and handle. this is $80 shipped. the downside to this kit is that the rod is redundant if you decide later to upgrade to a full kit. in stock 20? available

I have 372 exclusive kits available. if you just want to put together a 372 (or 365, 385/390), I can send you a 372 specific rod, large sleeve, and nut and washer and handle. this is $80 shipped. the downside to this kit is that the rod is redundant if you decide later to upgrade to a full kit. IN STOCK 10 available

Which Rod Goes With Which Saw?

Here is the color coding key to which rod in the Crankcase Assembly Tools Kit goes with which saw. (To be updated periodically.) CLICK TO EXPAND…

TIPS for Crankcase Assembly Tool Kit Use

1. Once you have the bearings properly positioned in the crankcases (by whatever means you choose), THEN use these tools.
2. Do NOT use the small sleeve on saws that use 6203 or larger bearings. if you do, you will mushroom the sleeve, instead, use the large sleeve (even on the flywheel side where the rod outer diameter is smaller than the inner diameter of the sleeve… it will be fine) on large saws.
3. One oddity about these rods is that the flywheel side rod is 5/8″ diameter not 3/4″ and this is one of the biggest design changes. The 5/8″ rod will work with the large sleeve, and if you want to shim it because it’s sloppy fit in the 3/4″ sleeve, just wrap 10x wraps of electrical tape, but it really doesn’t need a shim. Obviously the 5/8″ rod will work with the 5/8″ sleeve.
4. Do a dry run. Especially on your first time with a kit, this is invaluable. All of this information looks confusing but I assure you its simple and once you do it yourself a single time you’ll get it. Before you try pulling the crank into a bearing (which is in the crankcase and by extension the crankcase halves together), make sure the rods fit on the crank, and you know what sleeve you will be using.

How To Buy a Crankcase Assembly Tool Kit
You can do PAYPAL ….. FRIENDS AND FAMILY ONLY ( dockw01268@gmail.com), OR a POSTAL MONEY ORDER is fine. here is my address:

Matthew K. Olson DMD
1102 Fienemann Rd.
Farmington, CT 06032

Tools will be shipped USPS priority to the lower 48 (included in the price of the main kit)… for those international customers, it’s gonna be quite pricey, and may take a long time to get to you. Please consider that before placing your order.

I will guarantee to ship it out … I WILL NOT guarantee that you get the tool. For those international people, the risk is on you. Last time I shipped to Australia/EUROPE it was $40 additional. Canada is $30 additional. Recently it cost $70 just to ship to NEW ZEALAND… I reserve the right to add on additional shipping fees if shipping becomes that expensive.