Chainsaw Repair

while installing a new 20" chail on my 455 Rancher, I must have had my chain brake lever in the wrong position when removing the side cover. Now, I can't get the side cover back on. Seems the chain brake strap will not go over the clutch. What can I do?

Look at this cover where the circle is. Go to back side and look inside the circle at the 3 star silver metal * where you brake handle goes into.
You need to turn that to open the brake band back up in cover. Redneck fix take a old socket or swrench and cut it to fit the 3 prong metal star and turn to open brake band.

Look at back pic

http://www.ebay.com/itm/Husqvarna-455-460-Chain-Saw-Clutch-Cover-537286301-/110753494314?pt=LH_DefaultDomain_0&hash=item19c96c352a

Somewhere I saw a youtube video of a guy who showed a simple way to reset that little 3 pointed star. I can't remember exactly, but he basically held the clutch cover on "almost in place" where it goes, paying special attention to squeezing the silver 3 pointed star on to it's mating half on the saw body, then flipping the break release handle on or off (I forget which).

Basically, he was using the mating section on the body as the "wrench" to get the 3 pointed start into position.

I'm sure I'm not remembering it right, but it was a great no-tools-required way of re-setting this. I know my description leaves a lot to be desired. I'm hoping it sparks a memory for someone else...

I have personally been through the steps of that last video.

I just went ahead and installed the final spring cover before resetting the over-center mechanism. 

I also put the whole chain cover in a padded vice to install the spring and to re-set the over center mechanism.

The spring has to have something partially down through its center at installation or it will buckle and jump out of the slot.

Often when someone forces a chain cover off with the brake engaged, they distort the brake band and it will not seat in the pocket area anymore.
This will require replacement of the band which is not very expensive but the labor technique is generally not easy as has been described.

I've had to remove the brake lever from the saw and with the chain cover in a padded vice, use the bare brake lever to release the chain brake.

Then re-install the lever on the saw and then the side cover.

I made a tool out of a long handled spark plug tool.  Cut out every other side about 1/2' deep.
Shep