Poulan Chain Saw Repair

Poulan chain saws use many different components and parts. If any of these aren't working properly, you will encounter different kinds of problems. The basic three things that all two cycle engines need to start and run are fuel, spark and air compression. If one of these crucial elements are missing, then your saw will not run, and there are many different parts, which correlate to these three areas. Identifying the problem, whether fuel, spark or air compression, will allow you to isolate the parts that are malfunctioning. Use these simple troubleshooting tests to help find your problem.

Things You'll Need

• Leather work gloves
• Diesel fuel
• Toothbrush
• Screwdriver
• Spark plug wrench
• Starter fluid
• Carburetor cleaner

Instructions

Before Disassembly

1. Release the chain brake and, wearing gloves, ensure the chain moves easily around the bar. The chain should not stick in places or require a lot of force to move it around the bar.

2. Remove and clean the air filter. Slap the felt band across your palm or other flat surface to shake off all of the sawdust. Pour a little gasoline onto the filter and clean it with a toothbrush. Replace the filter if it looks old or is too dirty to clean.

3. Remove old, stale gasoline from the gas tank if it has been sitting in the chainsaw for more than a week. Empty out all of the gas and use carburetor cleaner, a toothbrush and rag to remove any old gas deposits from the tank.

4. Fill the chain saw with fresh gas at a 50:1 gas-oil mixture. Ensure there is enough bar oil in the oil reservoir. If the saw starts but dies while throttled, try adjusting the high and low RPM needle valves. This controls the fuel mixture in the carburetor and, if it isn't adjusted properly, will cause poor performance in your saw.

Air Compression Test

1. Ensure that the saw has air compression by pulling on the starter cord; if the saw has compression, the engine will make a whirring or chugging noise.

2. Place the saw on the ground and your right foot on the throttle's handle if the saw doesn't sound like it has compression. Place one hand on top of the saw's body and, with the other, pull on the cord again.

3. Check that the cord isn't too hard or too easy to pull. You should not have to strain to pull the cord out nor should it pull out without any resistance. The cord should also recoil back inside the engine without any assistance.

4. Take off the side cover with the screwdriver if the pull cord isn't working properly. Ensure the pull cord is attached properly and isn't frayed or broken. Replace the pull cord if it is damaged in any way.

Spark Test

1. Check the chain saw’s spark plug if the saw has compression but still won’t start after checking the pull cord.

2. Remove the rubber plug wire from the spark plug. Unscrew and take out the spark plug with a spark plug wrench.

3. Clean the spark plug by pouring diesel fuel over it. Scrape the spark plug's head with the toothbrush to remove any debris or dirt. Make sure the spark plug's gap is completely free of dirt. Wipe off the dirt and grime with a rag.

4. Reconnect the spark plug back into the plug connector but don’t attach the spark plug’s rubber plug wire to the engine. Let the plug wire hang loose, close to a metal part on the saw’s engine block.

5. Pull the starter cord slowly and look at the spark plug to see if there is a spark across the two metal points. If there isn’t one, replace the spark plug and test again. If you still don’t see a spark, check the wires to make sure they aren't damaged. If the wires are functional, remove and replace the starter’s coil or the starter.

Fuel Test

1. Remove the saw’s air filter cover and the air filter. Depress the throttle trigger to open the carburetor (the little metal flap that opens and closes when you squeeze the trigger). Spray starter fluid into the hole.

2. Restart the saw. If it still doesn’t start, pull the fuel filter and fuel line from the gas tank. Check the fuel line to make sure it isn't cracked or damaged. Replace the fuel filter and fuel line if they are dirty or damaged in any way.

3. Remove, disassemble and clean the carburetor if the saw still doesn’t start after cleaning and replacing the fuel line. Replace all of the seals and gaskets inside the carburetor. If it still doesn’t start after a thorough cleaning, you will need to replace the carburetor.

Tips & Warnings

• A majority of a saw's problems are connected to a dirty, broken or old carburetor.

• Storing saws for a long period of time will cause stale gasoline to dry up in the carburetor, which will need to be cleaned for the saw to run properly.

• If the saw still isn't working after completing these tests, you likely have something more serious going on inside the engine, such as a broken piston or cracked engine block, which will require a professional to fix.

• Always use caution when working around gasoline and sparks.

• Only perform maintenance on saws in a well-ventilated area.

References

• Lawn and Garden Manuals Online: Poulan Chainsaw Manuals
• Repair Spot: Two Stroke Engine and Carburetor Troubleshooting