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From what I see you will need assemble thing leaving the main spring and brake cover off. Before attempting to put the main back in install a clutch drum inside the brake band. Then you slip on the main spring and pry the end on with a flat blade screw driver. Now install in the cover for the spring and brake. Reset the chain brake and remove the drum.
Now install the chain brake on the saw and test. Do not trip the chain brake without the clutch drum in place. If these are anything like the Husqvarna version after they get worn they will get where it is nearly impossible to reset.
The chainbrake has activated, you need to load the brake, the best way is to clamp the cover in a vice, be carfull not to damage it, remove the hand guard from the saw, now use this as a tool to fit into the brake mechanism and load the brake, it will take a fair amount of force as there is a large compression spring under the cover.
You need to load the brake, clamp it in a vice, be carefull not to damage the cover, if the hand gaurd is connected to the brake pull it fully back until the locks off, this may take a fair amount of force as it is compressing a large spring, if the hand guard is on the machine, remove it and use this as a tool to load the brake, the only other way is to remoce the clutch and sprocket, now refit the brake onto the saw, now pull the hand guard fully back to load the brake.
To re assemble the hand guard back onto the brake cover, place the hand guard as best you can onto the side cover, now use a conical punch to push throught the hand guard and cover, now useing the punch as a pivot pull the hand guard fully back until the brake loads, once loaded remove the puch, the hand guard should now easily align back onto the cover, insert the two puvot collers and re fit the allen screw.
Tools you will need: 1/2 Socket (to remove bar nuts) T25(torq) or you can use a Flathead screw driver but is a little harder.
Remove 2 bar nuts,Clutch cover,bar,chain, 2 screws on black bar handle right behind clutch cover(this is needed because there is a hidden screw there for the chain break) You will need a new chain brake (my guess is that it is part # 530071893 aprox $15) but you will want to verify that with your model number.
You should see the chain break assembly, 3 - T25 screws are visible after the clutch cover is removed(note sometimes you have to clean saw dust to make screw head visible) the other T25 screw is hidden under the black bar handle. Once you remove all 4 screws on the chain brake you will be able to pull it off.
Installing the new one is the tricky part because if it is set(or break is on) you will have a hard time putting it on.One of the easiest ways is to focus on it near the muffler you will see that a metal 3 pronged gear fits into the plastic part of the chain break handle.and if the band is too tight to fit over the clutch drum you will have to carefully reset it by applying pressure onto the area that has the 3 pronged gear and chain break handle make sure that the handle is pushed forward all the way while you apply pressure then slowly pull chain break handle back till you hear a "snap" this resets the chain brake spring and the band should now fit over the clutch drum.Now, proceed with putting back together 4 chain brake assembly screws,2 handle screws,and bar,chain,clutch cover,and 2 bar nuts.
Please note it is important that you apply quite a bit of pressure onto chain break area where metal (3 pronged) gear fits into handle while resetting or when you reset it the metal part can cut into and damage the plastic piece in the chain break handle.
You can see a breakdown here: http://www.searspartsdirect.com/partsdirect/part-model/Poulan-Parts/Chainsaw-Parts/Model-P4018WT/1324/1503220/P0506041/00002?blt=06&prst=0&shdMod=P4018WT
I guarantee you are not the first to experience this. In the future if the clutch cover is difficult to remove please do not! Reset Chain Brake Immobilize the clutch cover (blocks of wood on a flat surface to protect the finish) in a vise or with a large C-clamp to a work surface.
Use pliers or a crescent wrench and rotate it clockwise until it latches open. This will require some force. A slight modification reported in a testimonial to the above method follows; " Thanks for the help. I took your answer and modified the fix a little. I placed the cover on loosely and then moved the bar handle into the right position in order to engage the spoked wheel, then rotated the handle back until the cover fit right. Thanks, SG " – NameRemoved
If you have more questions or need additional help please reply below and I will get back to you. HTH & Good Luck. Lou Thank You for using FixYa.
Ensure it isn't tripped before removal is the best advise I can give. It is difficult to reset with the cover removed, Dolfoff explains it well. GL Lou Reset Chain Brake
Please follow this link, cursor down to “Best Solution”, while there click the “Was this helpful? [Yes}” button. http://www.fixya.com/support/t3102817-re_install_side_cover_after_chain HTH
If no vice a "C" - clamp to a work surface might work.
Your cover probably won't go back on because the kickback/chain brake is on. Pull the handle on the cover back until you hear a click, the it will go on. As for removing the clutch, you need Poulan tool # 530031112 and an impact witha 3/4 socket. If you're just trying to reset chain break, removing clutch is not necessary, just pull back on handle as I said before.
That metal band you see which is preventing you from putting on the cover is part of the chain break mechanism. You were suppose to disengage the break before taking off the cover (I did the same thing). To get it back together you need to disengage the break by a tricky procedure and that will make the band diameter larger so it fits over the clutch. To force the band open, you need to first place the cover over the two bolts that hold the bar. As you already know, the back of the cover will not be able to fit over the clutch. Now in this angled position, bend (force) the break lever down (gray thing on top) until you can force together the sproket in the cover onto the mating pastic fitting built into the break lever. Now you can use the break lever to force down the internal spring and open the metal band. That will expand the stainless steel band and it will fit around the clutch. If you now push down on the back of the cover it will snap in over the clutch. Once you see how it is done, it is not so hard, but it is tricky because you are forcing some of the parts slightly out of position to get it back together. .
I used applman08's solution. A few pointers:
0. This problem occurs when you take off the side cover while the brake is set. So after you fix this, don't do that again.
1. When removing the clutch, place the screwdriver in the notch next to where it says "off" and tilt the screwdriver down so that when you strike it you are applying a clockwise shock force that is almost horizontal (assuming your 455 is on its side).
2. DO NOT remove the spring! There is a plastic housing that basically holds the brake mechanism in place (secured by 4 screws). If you take that apart, and then take out the spring, you will be learning how the brake works and spending some time compressing that spring and getting it back in. You'll have to come up with something clever to get the spring in depending on tools available.
3. Going back to 1. - get that clutch off, put the side cover back on, getting that brake lever lined up with the very-difficult-to-grab three-toothed mechanism for engaging the spring. Tighten down the side cover, or hold it snug with one hand while you lever the brake handle with the other. You will hear a satisfying snap as the braking mechanism (with the spring I told you not to mess with) resets.
Note: You can probably reset the braking mechanism by manually turning that three toothed gizmo but it's really hard to grab and the brake handle fits it perfectly. The key is you've got to turn that about 60 degrees.
Good luck, this was an annoying problem.