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Always wear appropriate ear protection, eye protection and head protection.
XX_
Measured maximum kickback value without chain brake for the bar
and chain combination on the label.
Starting Reminder
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
2
SAFETY RULES
OPERATE YOUR SAW SAFELY
WARNING: Always disconnect S Do not operate a chain saw with one hand.
spark plug wire and place wire where it can- Serious injury to the operator, helpers, by-
not contact spark plug to prevent accidental standers or any combination of these per-
starting when setting up, transporting, ad- sons may result from one-handed opera-
justing or making repairs except carburetor tion. A chain saw is intended for
adjustments. two-handed use.
Because a chain saw is a high-speed wood- S Operate the chain saw only in a well-venti-
cutting tool, special safety precautions must lated outdoor area.
be observed to reduce the risk of accidents. S Do not operate saw from a ladder or in a tree.
Careless or improper use of this tool can S Make sure the chain will not make contact
cause serious injury. with any object while starting the engine.
PLAN AHEAD Never try to start the saw when the guide
S Read this manual carefully until you com- bar is in a cut.
pletely understand and can follow all safety S Do not put pressure on the saw at the end of
rules, precautions, and operating instruc- the cut. Applying pressure can cause you to
tions before attempting to use the unit. lose control when the cut is completed.
S Restrict the use of your saw to adult users S Stop the engine before setting the saw down.
who understand and can follow safety S Do not operate a chain saw that is dam-
rules, precautions, and operating instruc- aged, improperly adjusted, or not com-
tions found in this manual. pletely and securely assembled. Always
S Wear protective gear. Always use steel- replace bar, chain, hand guard, or chain
toed safety footwear with non-slip soles; brake immediately if it becomes damaged,
snug-fitting clothing; safety chaps; heavy- broken or is otherwise removed.
duty, non-slip gloves; eye protection such S Hand carry saw only when engine is
as non-fogging, vented goggles or face stopped. Carry with muffler away from body;
screen; an approved safety hard hat; and guide bar and chain projecting behind you;
sound barriers (ear plugs or mufflers) to guide bar covered with a scabbard.
protect your hearing. Regular users MAINTAIN YOUR SAW IN GOOD
should have hearing checked regularly as WORKING ORDER
chain saw noise can damage hearing. Se- S Have all chain saw service performed by a
cure hair above shoulder length. qualified service dealer with the exception
Hearing Safety Hat of the items listed in the maintenance sec-
Protection tion of this manual. For example, if improp-
Eye er tools are used to remove or hold the fly-
Protection wheel when servicing the clutch, structural
Snug Fitting damage to the flywheel can occur and
Clothing Heavy Duty cause the flywheel to burst.
Gloves S Make certain the saw chain stops moving
when the throttle trigger is released. For
correction, refer to CARBURETOR AD-
JUSTMENT.
Safety Chaps S Never modify your saw in any way.
Safety Shoes S Keep the handles dry, clean, and free of oil
or fuel mixture.
S Keep fuel and oil caps, screws, and fas-
teners securely tightened.
S Keep all parts of your body away from the S Use only Poulan PRO accessories and re-
chain when the engine is running. placement parts as recommended.
S Keep children, bystanders, and animals a HANDLE FUEL WITH CAUTION
minimum of 30 feet (10 meters) away from S Do not smoke while handling fuel or while
the work area. Do not allow other people operating the saw.
or animals to be near the chain saw when S Eliminate all sources of sparks or flame in
starting or operating the chain saw. the areas where fuel is mixed or poured.
S Do not handle or operate a chain saw when There should be no smoking, open flames,
you are fatigued, ill, or upset, or if you have or work that could cause sparks. Allow en-
taken alcohol, drugs, or medication. You gine to cool before refueling.
must be in good physical condition and men- S Always have fire extinguishing tools avail-
tally alert. Chain saw work is strenuous. If able if you should need them.
you have any condition that might be aggra- S Mix and pour fuel in an outdoor area on
vated by strenuous work, check with your bare ground; store fuel in a cool, dry, well
doctor before operating a chain saw. ventilated place; and use an approved,
S Carefully plan your sawing operation in ad- marked container for all fuel purposes.
vance. Do not start cutting until you have a Wipe up all fuel spills before starting saw.
clear work area, secure footing, and, if you S Move at least 10 feet (3 meters) from fuel-
are felling trees, a planned retreat path. ing site before starting engine.
3
S Turn the engine off and let saw cool in a REDUCE THE CHANCE OF
non-combustible area, not on dry leaves, KICKBACK
straw, paper, etc. Slowly remove fuel cap S Recognize that kickback can happen.
and refuel unit. With a basic understanding of kickback,
S Store the unit and fuel in an area where fuel you can reduce the element of surprise
vapors cannot reach sparks or open which contributes to accidents.
flames from water heaters, electric motors S Never let the moving chain contact any ob-
or switches, furnaces, etc. ject at the tip of the guide bar.
KICKBACK S Keep the working area free from obstruc-
tions such as other trees, branches, rocks,
WARNING: Avoid kickback which fences, stumps, etc. Eliminate or avoid
can result in serious injury. Kickback is the any obstruction that your saw chain could
backward, upward or sudden forward motion hit while you are cutting. When cutting a
of the guide bar occurring when the saw branch, do not let the guide bar contact
chain near the upper tip of the guide bar con- branch or other objects around it.
tacts any object such as a log or branch, or S Keep your saw chain sharp and properly
when the wood closes in and pinches the tensioned. A loose or dull chain can in-
saw chain in the cut. Contacting a foreign ob- crease the chance of kickback occurring.
ject in the wood can also result in loss of Follow manufacturer’s chain sharpening
chain saw control. and maintenance instructions. Check ten-
S Rotational Kickback can occur when the sion at regular intervals with the engine
moving chain contacts an object at the upper stopped, never with the engine running.
tip of the guide bar. This contact can cause Make sure the bar nuts are securely tight-
the chain to dig into the object, which stops ened after tensioning the chain.
the chain for an instant. The result is a light- S Begin and continue cutting at full speed. If
ning fast, reverse reaction which kicks the the chain is moving at a slower speed, there
guide bar up and back toward the operator. is greater chance of kickback occurring.
S Pinch-Kickback can occur when the the S Cut one log at a time.
S Use extreme caution when re-entering a
wood closes in and pinches the moving previous cut.
saw chain in the cut along the top of the S Do not attempt cuts starting with the tip of
guide bar and the saw chain is suddenly the bar (plunge cuts).
stopped. This sudden stopping of the S Watch for shifting logs or other forces that
chain results in a reversal of the chain could close a cut and pinch or fall into chain.
force used to cut wood and causes the S Use the Reduced--Kickback Guide Bar
saw to move in the opposite direction of the and Low--Kickback Chain specified for
chain rotation. The saw is driven straight your saw.
back toward the operator.
S Pull-In can occur when the moving chain MAINTAIN CONTROL
contacts a foreign object in the wood in the
cut along the bottom of the guide bar and the Stand to the
saw chain is suddenly stopped. This sudden left of the saw
stopping pulls the saw forward and away
from the operator and could easily cause the
operator to lose control of the saw.
Avoid Pinch-- Kickback: Thumb on
underside of
S Be extremely aware of situations or ob- handlebar
structions that can cause material to pinch Never reverse
the top of or otherwise stop the chain. hand positions
S Do not cut more than one log at a time.
S Do not twist the saw as the bar is with-
drawn from an undercut when bucking.
Avoid Pull-- In:
S Always begin cutting with the engine at full
speed and the saw housing against wood.
S Use wedges made of plastic or wood.
Never use metal to hold the cut open. Elbow locked
Kickback Path
Thumb on underside of
handlebar
Avoid Obstructions S Keep a good, firm grip on the saw with both
hands when the engine is running and don’t
let go. A firm grip will help you reduce kick-
back and maintain control of the saw. Keep
Clear The the fingers of your left hand encircling and
Working Area your left thumb under the front handlebar.
Keep your right hand completely around the
4
rear handle whether your are right handed or
left handed. Keep your left arm straight with
the elbow locked. Can Obstruct Material
S Position your left hand on the front handle-
Not a Low--- Kickback Chain
bar so it is in a straight line with your right
hand on the rear handle when making S Front Hand Guard, designed to reduce the
bucking cuts. Never reverse right and left chance of your left hand contacting the chain
hand positions for any type of cutting. if your hand slips off the front handlebar.
S Stand with your weight evenly balanced on S Position of front and rear handlebars, de-
both feet. signed with distance between handles and
S Stand slightly to the left side of the saw to “in-line” with each other. The spread and “in-
keep your body from being in a direct line line” position of the hands provided by this
with the cutting chain. design work together to give balance and re-
S Do not overreach. You could be drawn or sistance in controlling the pivot of the saw
thrown off balance and lose control of the back toward the operator if kickback occurs.
saw. CHAIN BRAKE AND CKA ANGLE
S Do not cut above shoulder height. It is diffi- S Chain Brake, designed to stop the chain in
cult to maintain control of saw above the event of kickback.
shoulder height.
KICKBACK SAFETY FEATURES WARNING: WE DO NOT REP-
RESENT AND YOU SHOULD NOT AS-
WARNING: The following features SUME THAT THE CHAIN BRAKE WILL
are included on your saw to help reduce the PROTECT YOU IN THE EVENT OF A KICK-
hazard of kickback; however, such features BACK. Kickback is a lightning fast action which
will not totally eliminate this danger. As a throws the bar and rotating chain back and up
chain saw user, do not rely only on safety de- toward the operator. Kickback can be caused
vices. You must follow all safety precautions, by allowing contact of the bar tip in the danger
instructions, and maintenance in this manual zone with any hard object. Kickback can also
to help avoid kickback and other forces be caused by pinching the saw chain along the
which can result in serious injury. top of the guide bar. This action may push the
S Reduced--Kickback Guide Bar, designed guide bar rapidly back toward the operator. Ei-
with a small radius tip which reduces the ther of these events may cause you to lose
size of the kickback danger zone on the control of the saw which could result in serious
bar tip. A Reduced--Kickback Guide Bar injury or even death. DO NOT RELY UPON
has been demonstrated to significantly re- ANY OF THE DEVICES BUILT INTO YOUR
duce the number and seriousness of kick- SAW. YOU SHOULD USE THE SAW PROP-
backs when tested in accordance with ERLY AND CAREFULLY TO AVOID KICK-
safety requirements for gasoline powered BACK. Reduced--kickback guide bars and
chain saws as set by ANSI B175.1. low--kickback saw chains reduce the chance
Reduced Kickback Symmetrical Guide Bar and magnitude of kickback and are recom-
mended. Your saw has a low kickback chain
and bar as original equipment. Repairs on a
chain brake should be made by an authorized
servicing dealer. Take your unit to the place of
purchase if purchased from a servicing dealer,
Small Radius Tip
or to the nearest authorized master service
dealer.
Symmetrical Guide Bar S Tip contact in some cases may cause a light-
ning fast reverse REACTION, kicking guide
bar up and back toward operator.
S Pinching the saw chain along the top of the
guide bar may push the guide bar rapidly
Large Radius Tip back toward the operator.
S Low--Kickback Chain, designed with a S Either of these reactions may cause you to
contoured depth gauge and guard link lose control of the saw which could result in
which deflect kickback force and allow serious injury. Do not rely exclusively upon
wood to gradually ride into the cutter. Low-- devices built into your saw.
Kickback Chain has met kickback per-
formance requirements when tested on a WARNING: Computed kickback
representative sample of chain saws be- angle (CKA) listed on your saw and listed in the
low 3.8 cubic inch displacement specified CKA table below represents angle of kickback
in ANSI B175.1--2000. your bar and chain combinations will have
Contoured Depth Gauge when tested in accordance with CSA (Cana-
Elongated Guard Link
dian Standards Association) and ANSI stan-
dards. When purchasing replacement bar and
Deflects
chain, considerations should be given to the
kickback force lower CKA values. Lower CKA values repre-
Low--- Kickback and allows wood sent safer angles to the user, higher values in-
Chain to gradually ride dicate more angle and higher kick energies.
into cutter Computed angles represented indicate total
5
energy and angle associated without activation The following guide bar and chain combina-
of the chain brake during kickback. Activated tions meet kickback requirements of CSA
angle represents chain stopping time relative to Standards Z62.1, Z62.3, & ANSI B175.1 when
activation angle of chain break and resulting used on saws listed in this manual. Use of bar
kick angle of saw. In all cases lower CKA val- and chain combinations other than those listed
ues represent a safer operating environment is not recommended and may not meet the
for the user. CKA requirements per standard.
Computed kickback angle (CKA) Table
BAR
MODEL P/N Length CHAIN P/N CKA without chain brake
PP5020AV 577179801 20″ 577180501 17_
NOTE: To comply with Federal OSHA Reg- U.S. forest land and the states of California,
ulations for Commercial Logging, a chain Idaho, Maine, Minnesota, New Jersey,
brake is required and shall not be removed or Oregon, and Washington require by law that
otherwise disabled. many internal combustion engines to be
SAFETY NOTICE: Exposure to vibrations equipped with a spark arresting screen. If you
through prolonged use of gasoline powered operate a chain saw in a state or locale where
hand tools could cause blood vessel or nerve such regulations exist, you are legally respons-
damage in the fingers, hands, and joints of ible for maintaining the operating condition of
people prone to circulation disorders or these parts. Failure to do so is a violation of the
abnormal swellings. Prolonged use in cold law. Refer to the SERVICE section for
weather has been linked to blood vessel maintenance of the spark arresting screen.
damage in otherwise healthy people. If Failure to follow all Safety Rules and
symptoms occur such as numbness, pain, Precautions can result in serious injury. If
loss of strength, change in skin color or texture, situations occur which are not covered in this
or loss of feeling in the fingers, hands, or joints, manual, use care and good judgement. If you
discontinue the use of this tool and seek need assistance, contact your authorized
medical attention. An anti-vibration system service dealer or call 1-800--554--6723.
does not guarantee the avoidance of these STANDARDS: This saw is listed by Under-
problems. Users who operate power tools on writer’s Laboratories, Inc., in accordance with:
a continual and regular basis must monitor ANSI B175.1-- 2000 American National
closely their physical condition and the Standards for Gasoline--Powered Chain
condition of this tool. Saws -- Safety Requirements
SPECIAL NOTICE: Your saw is equipped CSA Z62.1-- 03 Chain Saws -- Occupational
with a temperature limiting muffler and spark Health and Safety
arresting screen which meets the require- CSA Z62.3-- 04 Chain Saw Kickback Occu-
ments of California Codes 4442 and 4443. All pational Health and Safety
ASSEMBLY
Protective gloves (not provided) should be 1. Move ON/STOP switch to the STOP
worn during assembly. position.
NOTE: CHAIN BRAKE MUST BE 2. Disengage chain brake.
3. Loosen and remove the chain brake
DISENGAGED BEFORE CLUTCH nuts and the clutch cover from the saw.
COVER CAN BE REMOVED OR RE-
INSTALLED ON THE CHAIN SAW. NOTE: If clutch cover can not be easily re-
moved from the chain saw, ensure chain brake
TO DISENGAGE CHAIN BRAKE, is disengaged by pulling the front hand guard
PULL THE FRONT HAND GUARD back toward the front handle as far as possible.
BACK TOWARD THE FRONT HAN- 4. Attach the bumper spike with the two
DLE AS FAR AS POSSIBLE (SEE screws as shown.
ILLUSTRATION).
Disengaged
Bar
Nuts
Bar
Nuts CUTTERS MUST FACE IN
DIIRECTION OF ROTATION
Location of Cutters Depth Gauge
Shipping Spacer
5. An adjusting pin and screw is used to
adjust the tension of the chain. It is
very important when assembling the
bar that the pin located on the adjust-
ing screw aligns into the lower hole in Drive Links
the bar. Turning the screw will move 9. Place chain over and behind clutch
the adjustment pin up and down the drum, fitting the drive links in the clutch
screw. Locate this adjustment before drum sprocket.
you begin mounting the bar onto the 10. Fit bottom of drive links between the
saw. See following illustration. teeth in the sprocket in the nose of the
guide bar.
11. Fit chain drive links into bar groove.
Inside 12. Pull guide bar forward until chain is snug
view of in guide bar groove. Ensure all drive
Clutch links are in the bar groove.
Cover 13. Now, install clutch cover making sure
the adjusting pin is positioned in the low-
er hole in the guide bar. Remember this
pin moves the bar forward and back-
Adjustment located on Clutch Cover ward as the screw is turned.
6. Turn the adjusting screw by hand coun-
terclockwise until the adjusting pin just
touches the stop. This should allow the
pin to be near the correct position. Clutch
7. Slide guide bar on bar bolts until guide Cover
bar stops against clutch drum sprocket.
Lower Hole
Adjusting Pin
Guide Bar
7
14. Install bar nuts and finger tighten only. 3. Using bar tool, roll chain around guide bar
Once the chain is tensioned, you will to ensure all links are in bar groove.
need to tighten bar nuts. 4. Lift up tip of guide bar to check for sag.
CHAIN TENSION Release tip of guide bar, then turn ad-
(Including units with chain already installed) justing screw 1/4 turn clockwise. Repeat
until sag does not exist.
WARNING: Wear protective gloves
when handling chain. The chain is sharp and Adjusting Screw -- 1/4 Turn
can cut you even when it is not moving.
NOTE: When adjusting chain tension,
make sure the bar nuts are finger tight only.
Attempting to tension the chain when the bar
nuts are tight can cause damage.
5. While lifting tip of guide bar, tighten bar
Checking the tension: nuts securely with the bar tool.
Use the screwdriver end of the chain adjust-
ment tool (bar tool) to move chain around
guide bar. If the chain does not rotate, it is too
tight. If the chain is too loose, it will sag below
the bar.
Bar Nuts
Guide
Bar
8
OPERATION
KNOW YOUR CHAIN SAW
READ THIS INSTRUCTION MANUAL AND SAFETY RULES BEFORE OPERATING YOUR
CHAIN SAW. Compare the illustrations with your unit to familiarize yourself with the location of
the various controls and adjustments. Save this manual for future reference.
Front Hand Guard/ Front Handle
Chain Brake Starter Rope
ON/STOP
Switch Choke/
Chain Muffler Fast Idle
Lever
Bar
Sprocket
Bar Oil Fill Cap Primer Bulb
Hole Starter Housing Fuel Mix Fill Cap
Air Filter Cover
Cylinder Cover
Chain
Throttle Direction
Lockout of Travel
Rear
Handle Adjusting Screw
Guide Bar
Chain
Throttle Catcher
Trigger Clutch Cover Bar Nuts
Chain Adjustment Tool
(Bar Tool)
9
BEFORE STARTING ENGINE Genuine Poulan or Poulan PRO bar and chain
oil is recommended to protect your unit against
WARNING: Muffler is very hot dur- excessive wear from heat and friction. Poulan
ing and after use. Do not touch the muffler or or Poulan PRO oil resists high temperature
allow combustible material such as dry thinning. If Poulan or Poulan PRO bar and
grass or fuel to do so. chain oil is not available, use a good grade SAE
30 oil.
WARNING: Be sure to read the fuel S Never use waste oil for bar and chain lubri-
handling information in the safety rules sec- cation.
tion of this manual before you begin. If you do S Always stop the engine before removing
not understand the fuel handling information the oil cap.
do not attempt to fuel your unit. Seek help CHAIN BRAKE
from someone that does understand the in- Ensure chain brake is disengaged by pulling
formation or call the customer assistance the front hand guard back toward the front han-
help line at 1-800-554-6723. dle as far as possible. The chain brake must be
FUELING ENGINE disengaged before cutting with the saw.
WARNING: Remove fuel cap slowly WARNING: The chain must not
when refueling. move when the engine runs at idle speed. If
the chain moves at idle speed refer to CAR-
BURETOR ADJUSTMENT within this
HELPFUL TIP manual. Avoid contact with the muffler. A hot
To obtain the correct oil mix muffler can cause serious burns.
ratio, pour 3.2 ounces of To stop the engine move the ON/STOP
2-- cycle synthetic oil into switch to the STOP position.
one gallon of fresh gas.
To start the engine hold the saw firmly on the
ground as illustrated. Make sure the chain is
IMPORTANT: This equipment is designed free to turn without contacting any object.
to operate on unleaded gasoline with a minim-
um 87 octane (R+M/2 method), with ethanol
blended up to 10% maximum by volume Starter Rope Handle
(E-10). Before operation, gasoline must be
mixed with a good quality synthetic 2-cycle
air-cooled engine oil designed to be mixed at a Left Hand
ratio of 40:1. Poulan/WEED EATER brand on Front
synthetic oil is recommended. Mix gasoline Handle
and oil at a ratio of 40:1. A 40:1 ratio is obtained
by mixing 3.2 fluid ounces of oil with 1 gallon of
unleaded gasoline. DO NOT USE automotive
oil or marine oil. These oils will cause engine
damage. When mixing fuel, follow instructions
printed on container. Once oil is added to gas-
oline, shake container momentarily to assure Right Foot Through Rear Handle
that the fuel is thoroughly mixed. Always read
and follow the safety rules relating to fuel before
fueling your unit. Purchase fuel in quantities
that can be used within 30 days to assure fuel WARNING: Do not attempt to throw
freshness. or drop--start the chain saw. Doing so will put
the operator at risk of serious injury due to
CAUTION: Never use straight gasoline in loss of control of the chain saw.
your unit. This will cause permanent engine
damage and void the limited warranty. Do not IMPORTANT POINTS TO REMEMBER
use alternate fuels such as ethanol blends When pulling the starter rope, do not use the full
above 10% by volume (E-15, E-85) or any extent of the rope as this can cause the rope to
methanol blended fuel. Use of these fuels can break. Do not let starter rope snap back. Hold
cause major engine performance and durability the handle and let the rope rewind slowly.
problems. For cold weather starting, start the unit at
BAR AND CHAIN LUBRICATION FULL CHOKE; allow the engine to warm up
The bar and chain require continuous lubrica- before squeezing the throttle trigger.
tion. Lubrication is provided by the automatic NOTE: Do not attempt to cut material with
oiler system when the oil tank is kept filled. the choke/fast idle lever in the FULL CHOKE
Lack of oil will quickly ruin the bar and chain. position.
Too little oil will cause overheating shown by
smoke coming from the chain and/or discolor-
ation of the bar. In freezing weather oil will thick- HELPFUL TIP
en, making it necessary to thin bar and chain oil If your engine still does not
with a small amount (5 to 10%) of #1 Diesel start after following these
Fuel or kerosene. Bar and chain oil must be instructions, please call
free flowing for the oil system to pump enough 1-- 800-- 554-- 6723.
oil for adequate lubrication.
10
STARTING A COLD ENGINE (or warm DIFFICULT STARTING (or starting a
engine after running out of fuel) flooded engine)
NOTE: In the following steps, when the The engine may be flooded with too much fuel
choke/fast idle lever is pulled out to the full if it has not started after 10 pulls. Flooded en-
extent, the correct throttle setting for starting gines can be cleared of excess fuel by pushing
is set automatically. the choke/fast idle lever in completely (to the
OFF CHOKE position) and then following the
warm engine starting procedure listed above.
Ensure the ON/STOP switch is in the ON posi-
tion. Starting could require pulling the starter
ON/STOP rope handle many times depending on how
Switch badly the unit is flooded. If engine fails to start,
refer to the TROUBLESHOOTING TABLE or
Choke call 1-800-554-6723.
Lever CHAIN BRAKE
WARNING: If the brake band is worn
too thin it may break when the chain brake is
triggered. With a broken brake band, the chain
brake will not stop the chain. The chain brake
should be replaced by an authorized service
dealer if any part is worn to less than 0.020″
Primer Bulb (0.5 mm) thick. Repairs on a chain brake
should be made by an authorized service deal-
er. Take your unit to the place of purchase if
1. Move ON/STOP switch to the ON posi- purchased from a servicing dealer, or to the
tion. nearest authorized master service dealer.
2. Pull choke/fast idle lever out to the full S This saw is equipped with a chain brake.
extent (to the FULL CHOKE position). The brake is designed to stop the chain if
3. Slowly press primer bulb 6 times. kickback occurs.
4. Pull the starter rope sharply 5 times with S The inertia--activated chain brake is
your right hand. Then, proceed to the activated if the front hand guard is pushed
next step. forward, either manually (by hand) or
NOTE: If the engine sounds as if it is trying automatically (by sudden movement).
to start before the 5th pull, stop pulling and S If the brake is already activated, it is
immediately proceed to the next step. disengaged by pulling the front hand guard
5. Push the choke/fast idle lever in to the back toward the front handle as far as
HALF CHOKE position. possible.
CHOKE/FAST IDLE LEVER S When cutting with the saw, the chain brake
must be disengaged.
Disengaged
OFF
HALF Engaged
FULL
14
SERVICE
NOTE: It is normal for a small amount of oil
WARNING: Disconnect the spark to appear under the saw after engine stops.
plug before performing maintenance except Do not confuse this with a leaking oil tank.
for carburetor adjustments. S ON/STOP Switch -- Ensure ON/STOP
We recommend all service and adjustments switch functions properly by moving the
not listed in this manual be performed by an switch to the STOP position. Make sure en-
authorized or Master Service Dealer. gine stops; then restart engine and continue.
S Fuel Tank -- Do not use saw if fuel tank
shows signs of damage or leaks.
HELPFUL TIP S Oil Tank -- Do not use saw if oil tank shows
IMPORTANT: Have all signs of damage or leaks.
repairs other than the rec- CHECK FOR LOOSE
ommended maintenance
described in the instruction FASTENERS AND PARTS
manual performed by an S Bar Nuts
authorized service dealer. S Chain
If any dealer other than an authorized S Muffler
S Cylinder Shield
service dealer performs work on the S Air Filter
product, Poulan PRO may not pay for S Handle Screws
repairs under warranty. It is your re- S Vibration Mounts
sponsibility to maintain and perform S Starter Housing
general maintenance. S Front Hand Guard
CHECK CHAIN SHARPNESS
MAINTENANCE SCHEDULE A sharp chain makes wood chips. A dull
Check: chain makes a sawdust powder and cuts
Fuel mixture level . . . . Before each use slowly. See CHAIN SHARPENING.
Bar lubrication . . . . . . . Before each use CHECK GUIDE BAR
Chain tension . . . . . . . Before each use Conditions which require guide bar mainte-
Chain sharpness . . . . . Before each use nance:
For damaged parts . . . Before each use S Saw cuts to one side or at an angle.
For loose caps . . . . . . Before each use S Saw has to be forced through the cut.
For loose fasteners . . . Before each use S Inadequate supply of oil to bar/chain.
For loose parts . . . . . . Before each use Check the condition of guide bar each time
Inspect and Clean: chain is sharpened. A worn guide bar will
Bar . . . . . . . . . . . . . . . . Before each use damage the chain and make cutting difficult.
Complete saw . . . . . . . After each use After each use, ensure ON/STOP switch is
Air filter . . . . . . . . . . . . . Every 5 hours* in the STOP position, then clean all sawdust
Chain brake . . . . . . . . . Every 5 hours* from the guide bar and sprocket hole.
Spark arresting screen To maintain guide bar:
and muffler . . . . . . . . . . Every 25 hours* S Move ON/STOP switch to STOP.
Replace spark plug . Yearly S Loosen and remove bar nuts and clutch
Replace fuel filter . . . Yearly cover. Remove bar and chain from saw.
* Hours of Operation -- S Clean the oil holes and bar groove after
Each hour of operation is approximately each 5 hours of operation.
2 tanks of fuel.
Remove Sawdust From
Guide Bar Groove
GENERAL RECOMMENDATIONS
The warranty on this unit does not cover
items that have been subjected to operator
abuse or negligence. To receive full value Oil Holes
from the warranty, the operator must main-
tain unit as instructed in this manual. Various
adjustments will need to be made periodical- S Burring of guide bar rails is a normal
ly to properly maintain your unit. process of rail wear. Remove these burrs
S Once a year, replace the spark plug, air filter, with a flat file.
and check guide bar and chain for wear. A S When rail top is uneven, use a flat file to re-
new spark plug and air filter assures proper store square edges and sides.
air-fuel mixture and helps your engine run
better and last longer. File Rail Edges
CHECK FOR DAMAGED OR and Sides
WORN PARTS Square
Contact an authorized service dealer for re-
placement of damaged or worn parts. Worn Groove Correct Groove
15
Replace guide bar when the groove is worn, Knob Air Filter
the guide bar is bent or cracked, or when ex- Cover
cess heating or burring of the rails occurs. If re-
placement is necessary, use only the guide bar
specified for your saw in the repair parts list or
on the decal located on the chain saw. Air Filter
CHECK FUEL MIXTURE LEVEL Wire
S See FUELING ENGINE under the OP- Clamp
ERATION section.
LUBRICATION
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REPLACE SPARK PLUG TO SHARPEN CHAIN:
The spark plug should be replaced each 1. Move ON/STOP switch to the STOP
year to ensure the engine starts easier and position.
runs better. Ignition timing is fixed and non- 2. Check chain for proper tension. Adjust
adjustable. chain tension if necessary. See CHAIN
NOTE: This spark ignition system complies TENSION section.
with the Canadian standard ICES--002. 3. Sharpen cutters.
1. Loosen knob on air filter cover. Remove S To sharpen the cutters, position the
air filter cover. file holder level (10° ) so that it rests
2. Pull off the spark plug boot. on the top edges of the cutter and
3. Remove spark plug from cylinder and depth gauge.
discard. NOTE: The chain has both left and
4. Replace with Champion RCJ--7Y spark right hand cutters.
plug and tighten securely with a 3/4 inch
(19 mm) socket wrench. Spark plug gap File Holder
should be 0.025 inch (0.6 mm). File
5. Reinstall the spark plug boot.
6. Reinstall air filter cover. Tighten knob se-
curely. Cutter
Knob Depth Gauge 10°
Spark
Plug Air Filter S Align the 25° file holder marks paral-
Boot Cover lel with the bar and to the center of the
chain.
Cutter
25° Cutter
File Holder Line
S Sharpen cutters on one side of the
chain first. File from the inside of each
cutter to the outside. Then, turn the
chain saw around and repeat the pro-
cess for the other side of the chain.
REPLACE FUEL FILTER S File on the forward stroke only. Use 2
To replace fuel filter (part #530095646), drain or 3 strokes per cutting edge.
your unit by running it dry of fuel. Remove fuel S Keep all cutters the same length
cap and its connected retainer from tank. Pull when filing.
filter from tank and remove from line. Replace S File enough to remove any damage
and reassemble. to cutting edges (side plate and top
CHAIN ADJUSTMENT plate of cutter).
See CHAIN TENSION in ASSEMBLY section. All Cutters Remove Damage
CHAIN SHARPENING Same Length
STORAGE
S Lightly oil external metal surfaces and
WARNING: Perform the following guide bar.
steps after each use: S Oil the chain and wrap it in heavy paper or
S Allow the engine to cool, and secure the cloth.
unit before storing or transporting.
S Store chain saw and fuel in a well venti- FUEL SYSTEM
lated area where fuel vapors cannot reach Under FUELING ENGINE in the OPERA-
sparks or open flames from water heaters, TION section of this manual, see message
electric motors or switches, furnaces, etc. labeled IMPORTANT regarding the use of
S Store chain saw with all guards in place gasohol in your chain saw.
and position chain saw so that any sharp Fuel stabilizer is an acceptable alternative in
object cannot accidentally cause injury. minimizing the formation of fuel gum depos-
S Store chain saw well out of the reach of its during storage. Add stabilizer to the gaso-
children. line in the fuel tank or fuel storage container.
SEASONAL STORAGE Follow the mix instructions found on stabiliz-
Prepare your unit for storage at the end of the er containers. Run engine at least 5 minutes
season or if it will not be used for 30 days or after adding stabilizer.
more. Poulan/WEED EATER 40:1, 2-cycle engine oil
If your chain saw is to be stored for a period (air cooled) is blended with fuel stabilizer. If you
of time: do not use this oil, you can add a fuel stabilizer
S Clean saw thoroughly before storage. with 2--cycle engine oil to your fuel tank.
S Store in a clean dry area.
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S Replace spark plug with new one of rec-
HELPFUL TIP ommended type and heat range.
During storage of your gas/ S Clean air filter.
oil mixture, the oil will sepa- S Check entire unit for loose screws, nuts,
rate from the gas. and bolts. Replace any damaged, broken,
We recommend that you or worn parts.
shake the gas can weekly S At the beginning of the next season, use
to insure proper blending of only fresh fuel having the proper gasoline
the gas and oil. to oil ratio.
ENGINE OTHER
S Remove spark plug and pour 1 teaspoon S Do not store gasoline from one season to
of 40:1, 2-cycle engine oil (air cooled) another.
through the spark plug opening. Slowly S Replace your gasoline can if it starts to
pull the starter rope 8 to 10 times to distrib- rust.
ute oil.
TROUBLESHOOTING TABLE
WARNING: Always stop unit and disconnect spark plug before performing all of
the recommended remedies below except remedies that require operation of the unit.
TROUBLE CAUSE REMEDY
Engine will not 1. Ignition switch off. 1. Move ignition switch to ON.
start or will run 2. Engine flooded. 2. See “Difficult Starting” in
only a few Operation Section.
seconds after 3. Fuel tank empty. 3. Fill tank with correct fuel mixture.
starting. 4. Spark plug not firing. 4. Install new spark plug.
5. Fuel not reaching 5. Check for dirty fuel filter; replace.
carburetor. Check for kinked or split fuel line;
repair or replace.
Engine will 1. Idle speed requires 1. See “Carburetor Adjustment” in the
not idle adjustment. Service and Adjustments Section.
properly. 2. Carburetor requires 2. Contact an authorized service dealer.
adjustment.
Engine will not 1. Air filter dirty. 1. Clean or replace air filter.
accelerate, 2. Spark plug fouled. 2. Clean or replace plug and regap.
lacks power, 3. Chain brake engaged. 3. Disengage chain brake.
or dies under 4. Carburetor requires 4. Contact an authorized service dealer.
a load. adjustment.
Engine 1. Too much oil mixed with 1. Empty fuel tank and refill with
smokes gasoline. correct fuel mixture.
excessively.
Chain moves 1. Idle speed requires 1. See “Carburetor Adjustment” in the
at idle speed. adjustment. Service and Adjustments Section.
2. Clutch requires repair. 2. Contact an authorized service dealer.
LIMITED WARRANTY
Poulan PRO, a division of Husqvarna Con- This warranty is not transferable and does not
sumer Outdoor Products N.A., Inc., war- cover damage or liability caused by improper
rants to the original consumer purchaser that handling, improper maintenance or alteration,
each new Poulan PRO brand gasoline chain or the use of accessories and/or attachments
saw is free from defects in material and not specifically recommended by Poulan PRO
workmanship and agrees to repair or replace for this chain saw. This warranty does not cov-
under this warranty any defective gasoline er tune--up, spark plugs, filters, starter ropes,
chain saw as follows from the original date of chain sharpening, bars, chains, and other parts
purchase. which wear and require replacement with rea-
2 YEARS - Parts and Labor, when used for sonable use during the warranty period. This
household purposes. warranty does not cover predelivery setup,
60 DAYS - Parts and Labor, when used for installation of guide bar and chain, and normal
commercial, professional, or income pro- adjustments explained in the instruction manu-
ducing purposes. al such as chain tension adjustments. This
30 DAYS - Parts and Labor, if used for rental warranty does not cover transportation costs.
purposes.
19
In the event you have a claim under this war- NO CLAIMS FOR CONSEQUENTIAL OR
ranty, you must return the product to an au- OTHER DAMAGES WILL BE ALLOWED,
thorized service dealer. AND THERE ARE NO OTHER EXPRESS
Should you have any unanswered questions WARRANTIES EXCEPT THOSE EX-
concerning this warranty, please contact: PRESSLY STIPULATED HEREIN.
Poulan PRO, a division of Husqvarna SOME STATES DO NOT ALLOW LIMITA-
Consumer Outdoor Products N.A., Inc. TIONS ON HOW LONG AN IMPLIED WAR-
9335 Harris Corners Parkway RANTY LASTS OR THE EXCLUSION OR
Charlotte, NC 28269 LIMITATIONS OF INCIDENTAL OR CON-
1--800--554--6723 SEQUENTIAL DAMAGES, SO THE
In Canada, contact: ABOVE LIMITATIONS OR EXCLUSION
Poulan PRO MAY NOT APPLY TO YOU.
850 Matheson Blvd. West This is a limited warranty within the meaning
Mississauga, Ontario L5V 0B4 of that term as defined in the Magnuson--
Giving the model number, serial number and Moss Act of 1975.
date of purchase of your product and the The policy of Poulan PRO is to continuously
name and address of the authorized dealer improve its products. Therefore, Poulan
from whom it was purchased. PRO reserves the right to change, modify, or
THIS WARRANTY GIVES YOU SPECIFIC discontinue models, designs, specifications,
LEGAL RIGHTS, AND YOU MAY HAVE and accessories of all products at any time
OTHER RIGHTS WHICH VARY FROM without notice or obligation to any purchaser.
STATE TO STATE.
IMPORTANT: This product is compliant with U.S. EPA Phase 3 regulations for exhaust and evap-
orative emissions. To ensure EPA Phase 3 compliance, we recommend using only genuine Poulan
PRO brand replacement parts. Use of non-compliant replacement parts is a violation of federal law.
The information on the product label indicates which standard your engine is certified.
Example: (Year) EPA and/or CALIFORNIA.
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