MANUAL !! POULAN PRO CHAIN SAW SERVICE REPAIR 1900 1950 2050 2055 2075 2150 2175 2375 WILD THING 2250 2450 2550 220 221 221L
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For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 SERVICE MANUAL FOR POULAN – POULAN/PRO 33cc 34cc 36cc 40cc and 42cc 1900-1900LE-1950-1950LE-2050-2050LE-2055LE-2075 2075LE-2150-2150LE-2175-2175LE-2150-2150LE-2375 2375LE WILD THING-2250-2450-2550 POULAN PRO 220-221-221LE-260-260LE www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 SCREW TORQUE SPECIFICATIONS - AV ONLY PART NO. STARTER GROUP 530-015892 530-015920 530-016080 IGNITION GROUP 530-016134 530-015814 952-030150 CYLINDER GROUP 530-016132 530-016132 530-015875 530-016338 530-016359 530-015810 530-016101 530-015780 530-016153 530-015906 530-016018 530-016015 530-015814 530-015814 530-016179 530-015886 530-015906 530-015906 530-015814 CLUTCH GROUP 530-014949 530-015917 OILER GROUP 530-016064 LOCATION (QTY.) SIZE TORQUE IN-LB FAN HOUSING STARTER PULLEY ROPE SCREW M5.28 X 1.81 M5.25 X 1.81 M3.63 X 1.34 20-30 IN-LB 25-35 IN-LBS 5-10 IN-LB FLYWHEEL NUT MODULE SPARK PLUG M8 X 1 M5.28 X 1.81 M14 X 1.25 12-14 FT-LB 25-35 IN-LB 15-25 FT-LB CHASSIS/CYLINDER MUFFLER ISO SPRING/CYLINDER MUFFLER (LE) BRASS NUT COVER (LE) CARBURETOR & AIR BOX GROUP CARB. ADAPTER AIR FILTER NUT AIR PURGE CHASSIS, FUEL TANK & HANDLE GROUP CYLINDER SHIELD FRONT SPRING/CHASSIS FRONT SPRING/BAR SPRING ASSY/CHASSIS FRONT/REAR HANDLE REAR BOTTOM SPRING/HANDLE REAR TOP SPRING/HANDLE REAR SPRING HANDLE/COVER REAR HANDLE COVER REAR SPRING CHASSIS CHAIN CATCHER M6 X 1.0 M6 X 1.0 M4.85 X 1 M6X1.0 10 - 24 110-140 IN-LB 90-100 IN-LB 40-50 IN-LB 90-100 IN-LB 25-35 IN-LB 10 - 24 M5 X .08 6 - 19 40-50 IN-LB 25-35 IN-LB 10-15 IN-LB M4.8 X 1.6 M5.28 X 1.81 10 - 24 M5.25 X 1.81 M5.28 X 1.81 M5.28X1.81 10X14X1.06 M5.28 X 1.81 M5.28 X 1.81 M5.28-1.81 M5.28 X 1.81 CLUTCH ASSEMBLY BAR MOUNTING NUT M6 X 1.0 L.H. M8 X 1.25 10-15 FT-LB 10-20 FT-LB OIL PUMP M3.63 X 1.34 5-10 IN-LB www.mymowerparts.com 20-30 25-35 40-50 30-40 20-30 25-35 20-30 30-40 30-40 30-40 30-40 IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB IN-LB For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 PART NO. STARTER GROUP 530-015892 530-015920 530-016080 IGNITION GROUP 530-016134 530-015775 530-015814 530-030153 CYLINDER GROUP 530-016132 530-016132 530-016338 530-016359 CARB.& AIR BOX 530-015810 530-016101 530-015780 530-016153 530-015814 530-015940 530-015814 CLUTCH GROUP 530-014949 530-015917 OILER GROUP 530-016064 NON AV TORQUE SPEC. LOCATION SIZE TORQUE IN-LBS FAN HOUSING M5.28 X 1.81 STARTER PULLEY M5.28 X 1.81 ROPE SCREW M3.63 X 1.34 20-30 IN-LB 25-35 IN-LB 5-10 IN-LB FLYWHEEL NUT M8 X 1 SWITCH SPRING 8-16 MODULE M5.28 X 1.81 SPARK PLUG M14 X 1.25 12-14 FT-LB 25-35 IN-LB 25-35 IN-LB 15-25 FT-LB NON AV TORQUE SPEC. CHASSIS/CYLINDER MUFFLER MUFFLER (LE) BRASS NUT COVER (LE) M6 X 1.0 M6 X 1.0 M6 X 1.0 10-24 110-140 IN-LB 90-100 IN-LB 90-100 IN-LB 25-35 IN-LB CARB. ADAPTER 10-24 AIR FILTER NUT M5 X .08 AIR PURGE 6-19 CHASSIS,TANK & HANDLE CYLINDER SHIELD M4.8 X 1.6 (TOP) H-BAR/CHASSIS M5.26 X 1.81 (BOTTOM) H-BAR/CHASSIS 10-14 CHAIN CATCHER M5.28 X 1.81 40-50 IN-LB 25-35 IN-LB 10-15 IN-LB CLUTCH ASSEMBLY M6 X 1.0 L.H. BAR MOUNTING NUT 10-15 FT-LB 10-15 FT-LB OIL PUMP (2) M3.63 X 1.34 5-10 IN-LB NOTE: ALL TORQUES WILL BE IN IN-LBS UNLESS SPECIFYED IN (FT-LB) www.mymowerparts.com 20-30 22-32 22-32 30-40 IN-LB IN-LB IN-LB IN-LB For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 SUMMARY OF PERFORMANCE SPECIFICATION COMPRESSION (COLD) 36cc/40cc BARE/CHROME BARE CHROME 130-150 145-165 42cc LE AV/NON AV 125-145 CRANKSHAFT ENDPLAY IGNITION TIMING COIL AIR GAP 125-145 0.00-0.85 MM 27-32 BTDC .020/.038 LEAK CHECK CRANK CASE TO 5 PSI. DROP .05 PSI IN 1.5 SECONDS SPARK PLUG GAP .025 www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 1. CRANKSHAFT, PISTON, AND ROD ASSEMBLY A. CARE MUST BE TAKEN TO PROTECT SURFACE OF PISTON FROM NICKS AND SCRAPES. B. PISTON PIN ASSEMBLY FIXTURE MUST BE KEPT CLEAN TO AVOID DAMAGE TO THE PISTON. C. PISTON PINS MUST BE CLEAN AND FREE OF NICKS AND SCRATCHES. (DO NOT THROW OR SUBJECT TO SEVERE JOLTS DURING HANDLING.) D. CONNECTING ROD SHOULD REVOLVE FREELY AROUND CRANK PIN. E. PLACE A DROP OF POULAN 2-CYCLE ENGINE OIL ON CRANK PIN BEARING AND ON PISTON PIN BEARING AS SHOWN. IMPORTANT NOTE: USE SEAL PROTECTOR WHEN INSTALLING BEARING AND SEAL ASSEMBLY ONTO SHAFT. F. INSTALL BEARING AND SEAL ASSEMBLY ONTO CRANKSHAFT. NOTE: BEFORE INSTALLING SEALS, APPLY POULAN 2 -CYCLE ENGINE OIL AS SHOWN IN FIGURE B. G. INSTALL OILER WORM GEAR ONTO CRANKSHAFT WITH ASSEMBLY TOOL UNTIL COIL FALLS IN GROOVE. MAINTAIN COIL PITCH 2.59 - 2.92MM. (FIGURE C) (FIGURE C) NOTE; WORM GEAR INSTALLATION IS CRITICAL. USE TOOL PN 530031166 FOR CORRECT PITCH SPACING. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 2. CRANKSHAFT, PISTON, AND ROD ASSEMBLY - CONTINUED I. INSTALL PISTON PIN INTO PISTON BOSS, THROUGH PIN BEARING AND ROD, AND INTO OPPOSITE PISTON BOSS. (FIGURE D) J. INSTALL PISTON PIN RETAINERS (DYED RED). RETAINERS MUST BE SEATED COMPLETELY IN GROOVE AND NOT BENT . K. INSTALL PISTON RING IN PISTON RING GROOVE USING ASSEMBLY TOOL . ENSURE RING IS ORIENTED PROPERLY RELATIVE TO RING PEG (SEE FIG."D"). DO NOT OVER STRESS RING. (CAREFULLY INSTALL RING BY HAND IF TOOL IS NOT AVAILABLE.) IMPORTANT NOTE: BE CAREFUL WHEN INSTALLING PISTON AND ROD ASSEMBLY INTO CYLINDER TO PREVENT BREAKING THE PISTON RING. INSTALLATION ON PAGE 11. FIGURE D www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 3. CYLINDER ASSEMBLY A. ASSEMBLE CARB SEAL (#3 IN FIGURE E) ON CARB ADAPTOR (#1 IN FIGURE E) MAKING SURE TO ALIGN THE ALIGNMENT TAB ON CARB ADAPTOR AND ALIGNMENT HOLE ON CARB SEAL. ENSURE CARB SEAL IS FULLY SEATED ON CARB ADAPTOR. B. POSITION (2) CARB MOUNTING SCREWS (#1A IN FIGURE E) INTO THE CARB ADAPTOR. #1 IN FIGURE E. C. PLACE CARB GASKET ( #1B IN FIGURE E) OVER LOCATOR PINS ON CARB ADAPTOR. D. INSTALL CARB ADAPTOR ASSEMBLY ONTO CYLINDER. SECURE WITH TWO (2) SCREWS (#2 IN FIGURE E). TORQUE TO SPECIFICATION. E. CSI-AV ONLY: INSTALL TOP REAR ISOLATOR SPRING ASSEMBLY ONTO CYLINDER. SECURE WITH ONE (1) SCREW, TORQUE TO SPECIFICATION. FIGURE E www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 4. CYLINDER ASSEMBLY - CONTINUED SPARK PLUG ALIGNMENT PLATE CYLINDER CRANKSHAFT & PISTON ASSY. CRANKCASE CAP TINNERMAN NUT GROUND STRAP “U” CLIP HEAT SHIELD FIGURE F F. FIGURE G G. OIL RING AND INSTALL CRANKSHAFT, PISTON, AND ROD ASSEMBLY IN CYLINDER (FIGURE F). APPLY SMALL CONSISTENT BEAD OF SEALANT. BEAD MUST NOT BE "PUDDLED" OR ANY SKIPS. NO PART OF SEALING BEAD IS ALLOWED IN BEARING POCKETS. DO NOT LET SEALANT DRY OVER 5 MINUTES. (PRIOR TO ASSY. H. POSITION GROUND STRAP TO CHASSIS (FIGURE F). I. INSTALL THREE (3) TINNERMAN NUTS INTO CHASSIS POCKETS. J. INSTALL HEATSHIELD AS SHOWN. "U" CLIP IS USED TO SECURE HEAT SHIELD IN POSITION (LOW EMISSION ENGINES ONLY) (FIGURE F).. K. PLACE CRANKSHAFT ALIGNMENT PLATE INTO LOCATING HOLES ON CHASSIS. PLACE CHASSIS ON CYLINDER, ALIGNING CRANKSHAFT WITH PLATE. SECURE CYL. TO CHASSIS. TORQUE TO 100 IN/LB MIN. L. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 FIGURE H 1 ITEM 1 2 3 4 5 6 DESCRIPTION BODY, OIL PUMP ASS'Y , GEAR & PLUNGER BUSHING, OIL PUMP PIN, CAM RIVET BARREL, OIL PUMP www.mymowerparts.com QUANTITY 1 1 1 1 1 1 For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 7. OILER ASSEMBLY FIGURE (G) ITEM 1A 1B 1C 2 3 4 5 6 DESCRIPTION OILER PICK-UP OILER FILTER (SPRING) OIL FILTER PLUG ELBOW FITTING OIL PUMP ASSEMBLY SEAL BLOCK OILER SCREW BAR PLATE www.mymowerparts.com QUANTITY 1 1 1 1 1 1 1 1 For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 8. OILER ASSEMBLY - CONTINUED A. ASSEMBLE PLUG INTO PICKUP FILTER. B. ASSEMBLE FILTER ONTO PICKUP. C. CAREFULLY POSITION OILER PICKUP INTO CHASSIS. IMPORTANT NOTE: FAILURE TO INSTALL CORRECTLY WILL RESULT IN A NON-FUNCTIONING OILER. SEE FIGURE (G) FOR CORRECT POSITIONING OF PICKUP. D. INSTALL SEAL BLOCK ONTO PUMP BARREL. NOTE: HOLE IN TOP OF BLOCK WILL ALIGN WITH HOLE IN BARREL. E. PLACE ELBOW FITTING ON END OF SEAL BLOCK. F. INSTALL OIL PUMP ASSEMBLY WITH SEAL BLOCK AND ELBOW ONTO CHASSIS. G. CONNECT ELBOW FITTING TO PICKUP. H. USING TWO (2) SCREWS, TORQUE OIL PUMP ASSEMBLY TO SPECIFICATION. TORQUE TOP SCREW FIRST. I. INSTALL BAR PLATE. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 9. MUFFLER ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION CYLINDER HEAT INSULATOR BACKPLATE MUFFLER GASKET MUFFLER ASSEMBLY MUFFLER BOLT BACKPLATE(LE) DEFLECTOR(LE) MUFFLER ASSY.(LE) COVER-BOLT (LE) NUT-BRASS(LE) MUFFLER BOLT(LE) www.mymowerparts.com QUANTITY 1 1 1 1 1 2 1 1 1 1 1 2 For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 10. MUFFLER ASSEMBLY A. INSTALL HEAT INSULATOR INTO CYLINDER. NOTE: ITEMS #3, #4, #5, AND #6 MAY BE RECEIVED ASSEMBLED. IF SO, TORQUE TO SPECIFICATION. B. INSTALL MUFFLER PLATE. NOTE: THE SIDE OF PLATE STAMPED MUFFLER SIDE SHOULD BE PLACED TOWARD THE MUFFLER BODY, AND AWAY FROM THE CYLINDER. C. PLACE MUFFLER GASKET BETWEEN PLATE AND MUFFLER BODY. D. INSTALL THE TWO (2) MOUNTING SCREWS. TORQUE TO SPECIFICATION. IMPORTANT NOTE: MUFFLER HALVES MUST BE SEATED PROPERLY TO PREVENT LEAKS. 9. FLYWHEEL ASSEMBLY D. INSTALL FLYWHEEL, USING CARE TO ALIGN "CAST IN KEY" ON FLYWHEEL WITH THE KEYWAY ON CRANKSHAFT. THE CAST RECESS ON THE FLYWHEEL INDICATES THE POSITION OF THE "CAST IN KEY" (FIGURE H) FIGURE H E. INSTALL FLAT WASHER, AND NUT. TORQUE TO SPECIFICATION (FIGURE L). NOTE: IMPORTANT TO CLEAN CRANKSHAFT TAPER WITH A ALCOHOL DAMPENED CLOTH TO REMOVE GREASE. FAILURE TO DO THIS COULD CAUSE THE FLYWHEEL KEY TO SHEAR. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 11. IGNITION ASSEMBLY - NON -AV AND AV A. PRESS FLAG TERMINAL ONTO THE SPADE TERMINAL ON MODULE. B. POSITION UPPER MODULE SCREW THROUGH RING TERMINAL ON BLACK WIRE. POS ITION TERMINAL AGAINST EPOXY. C. INSTALL IGNITION MODULE WITH TWO (2) SCREWS. SET AIR GAP TO SPECIFICATION (.2MM - .38MM. TORQUE SCREWS TO SPECIFICATION . D. ROUTE WIRES AS SHOWN. IMPORTANT NOTE: DO NOT POSITION WIRE WHERE CYLINDER SHIELD SCREW WILL BE. E. F. ROUTE WIRES BETWEEN CYLINDER FINS. POSITION SPARK PLUG WIRE BY FINS, AND INSTALL CLIP (FIGURE I). POSITION SPARK PLUG BOOT TOWARD FLYWHEEL AT 7 -8 O'CLOCK TOWARD FAN HOUSING. ROUTE WIRES BETWEEN CARBURETOR ADAPTOR AND CHASSIS INT O AIR BOX. KILL SWITCH WIRE SHOULD BE ASSEMBLED BEHIND IGNITION WIRE. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 12. IGNITION ASSEMBLY - NON -AV ONLY - CONTINUED FIGURE I G. PLACE SCREW THROUGH RING TERMINAL ON BLACK WIRE, THEN THROUGH SWITCH SPRING. TORQUE TO SPECIFICATION. NOTE: RING TERMINAL MUST BE POSITIONED AGAINST BOSS DURING INSTALLATION (FIGURE J). H. INSTALL PLUG TERMINAL INTO KILL SWITCH. NOTE: THIS MAY BE DONE IN ADVANCE (FIGUREJ). I. MOVING THE SPRING BACK, SNAP THE KILL SWITCH INTO POSITION. FIGURE J www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 13. IGNITION ASSEMBLY - AV ONLY - CONTINUED FIGURE K J. PRESS TWO (2) WIRE TERMINALS ONTO TWO (2) SPADE TERMINALS ON BACK OF THE IGNITION SWITCH. NOTE: WIRES MAY BE PRE -ASSEMBLED ONTO SWITCH. K. SNAP IGNITION SWITCH INTO OPENING IN REAR OF THE LEFT CHASSIS (FIGURE K). IMPORTANT NOTE: ORIENT SWITCH WHERE THE “I” IS CLOSEST TO THE FAN HOUSING SIDE OF CHASSIS. ALSO, TERMINALS ARE CLOSEST TO THE FAN HOUSING SIDE. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 14. FUEL LINE AND PURGE BULB ROUTINGS IMPORTANT NOTE: MAXIMUM GAP BETWEEN END OF LINE, AND FITTING BASE TO BE 1.3MM (FIGURE L). A. CONNECT RETURN LINE (LARGER OF TWO LINES) FROM RIGHT HALF OF CHASSIS TO LARGE NIPPLE ON PURGE BULB. B. CONNECT PURGE LINE TO SMALL NIPPLE ON BULB. LAY INTO POSITION. C. NON-AV ONLY CONNECT PURGE LINE TO BRASS FITTING ON CARBURETOR. NON-AV ONLY CONNECT FUEL LINE FROM LEFT HALF OF CHASSIS TO BLACK PLASTIC FITTING ON CARBURETOR. D. AV ONLY CONNECT PURGE LINE TO BRASS FITTING ON ADJUSTMENT (LEFT) SIDE OF CARBURETOR. AV ONLY CONNECT FUEL LINE FROM LEFT HALF OF CHASSIS TO BRASS FITTING ON CHOKE LEVER (RIGHT) SIDE OF CARBURETOR. E. POSITION ALL LINES UNDER TAB ON CARB ADAPTOR (IF AVAILABLE). F. WHEN CHANGING PURGE BULB , CUT 1/16 FROM END OF FUEL LINE, RE INSTALL LINE. THIS WILL INSURE TIGHT FIT OF LINE ON TO THE BARB OF CARB. FIGURE L www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 15. AIR BOX ASSEMBLY - NON -AV ONLY ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION CARBURETOR GASKET THROTTLE WIRE CARBURETOR (WT -324) AIR BOX NUTS AIR FILTER (FOAM) CHOKE LEVER CHOKE GROMMET PURGE LINE PURGE BULB SCREWS -PURGE CARBURETOR GROMMET www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 16. AIR BOX ASSEMBLY - NON -AV ONLY - CONTINUED A. FIT CARBURETOR GASKET OVER SCREWS THROUGH CARBURETOR ADAPTOR. B. INSTALL THROTTLE WIRE INTO CARBURETOR THROTTLE PLATE, THEN TO TRIGGER (FIGURE M). C. DEPRESS TRIGGER TO POSITION CARBURETOR OVER STUDS. D. INSTALL CHOKE ROD GROMMET TO CHOKE ROD. E. ATTACH CHOKE ROD TO CARBURETOR (FIGURE M), THEN LAY GROMMET THROUGH OPENING IN CHASSIS. F. TORQUE PURGE BULB TO SPECIFICATION. G. INSTALL CARBURETOR GROMMET. FIGURE M H. POSITION AIRBOX. START NUTS BY HAND. TORQUE TO SPECIFICATION. I. OIL AIR FILTER USING 2 CYCLE OIL. INSTALL AIR FILTER. IMPORTANT NOTE: ALL EXCESS OIL MUST BE SQUEEZED FROM THE FILTER PRIOR TO INSTALLATION INTO THE AIR BOX. IMPORTANT NOTE: VERIFY THROTTLE LOCK, AND TRIGGER FUNCTION. IT MUST WORK FREELY, AND NOT STICK WHEN RELEASED. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 17. AIR BOX ASSEMBLY - AV ONLY - ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION CARBURETOR GASKET THROTTLE CABLE CARBURETOR AIR BOX NUTS AIR FILTER (FOAM) CHOKE GROMMET CHOKE LEVER PURGE LINE PURGE BULB SCREWS -PURGE CARBURETOR GROMMET THROTTLE CABLE GROMMET www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 18. AIR BOX ASSEMBLY - AV ONLY - CONTINUED FIGURE N FIGURE O A. INSTALL CARBURETOR GASKET OVER SCREWS THROUGH CARBURETOR ADAPTOR. B. INSTALL CHOKE ROD GROMMET, AND ATTACH CHOKE ROD TO CARBURETOR (FIGURE N). (CHOKE GROMMET CAN ONLY BE INSTALLED ONE WAY.) C. INSTALL CARBURETOR OVER SCREWS, POSITIONING CHOKE ROD GROMMET IN SLOT IN RIGHT CHASSIS. D. INSTALL CARBURETOR GROMMET. E. INSTALL THROTTLE CABLE ON AIR BOX BY PUSHING CONDUIT END INTO POCKET ON BOTTOM OF THE AIR BOX LOOPING BEHIND AIR BOX.(FIGURE O) F. INSTALL “Z” FITTING OF THROTTLE CABLE IN LOWER HOLE OF CARBURETOR THROTTLE LEVER (FIGURE P). G. POSITION AIR BOX OVER SCREWS, START NUTS BY HAND. TORQUE TO SPECIFICATION. NOTE: ENSURE THAT THROTTLE CABLE LOOP IS ROUTED UNDER THE CARBURETOR, AND OVER THE SWITCH WIRES, AND NOT CLAMPED BEHIND THE CARBURETOR. J. FIGURE P H. INSTALL FOAM AIR FILTER. I. INSTALL THROTTLE CABLE GROMMET ONTO THROTTLE CABLE, AND PLACE GROMMET INTO SLOT IN REAR OF CHASSIS ASSEMBLY. TORQUE PURGE BULB TO SPECIFICATION. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 19. FAN HOUSING ASSEMBLYAV ONLY . BAFFLE IS NOT USED ON MOST UNIT ITEM DESCRIPTION 1 FAN HOUSING 2 RECOIL SPRING 3 STARTER PULLEY 4 SCREW - PULLEY 5 ROPE & HANDLE ASSEMBLY 6 SCREW - ROPE ANCHOR 7 FAN HOUSING SCREWS 8 BAFFLE www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 20. FAN HOUSING ASSEMBLY AV & NON AV NO. 1 2 3 4 5 6 7 DESCRIPTION FAN HOUSING RECOIL SPRING STARTER PULLEY SCREW-PULLEY ROPE & HANDLE ASS'Y SCREW-ROPE ANCHOR SCREW-FAN HOUSING QUANTITY 1 1 1 1 1 1 4 www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 21. RECOIL SPRING ASSEMBLY A. PLACE RECOIL SPRING INTO FAN HOUSING, MAKING SURE THE HOOK IS POSITIONED AS SHOWN (FIGURE Q). FIGURE Q B. WIND UP PULLEY UNTIL IT STOPS, THEN UNWIND 1 TO 2 TURNS, AND ALIGN ROPE HOLE WITH FAN HOUSING EYELET. C. FEED ROPE THROUGH FAN HOUSING STARTER ROPE EYELET AND INTO PULLEY HOLE. LOOP ROPE COUNTERCLOCKWISE AROUND RATCHET AND TUCK LOOSE END BACK UNDER ROPE. POSITION END OF ROPE BETWEEN SCREW BOSS AND OUTER RETAINING RING. IMPORTANT NOTE: END OF ROPE SHOULD BE FLUSH TO 6.4MM PAST END OF RETAINING RIB (FIGURE R). D. ROPE MUST BE POSITIONED AGAINST PULLEY TOP FLANGE. FIGURE R www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 22. RECOIL SPRING ASSEMBLY - CONTINUED E. WITH ROPE FULLY EXTENDED, PULLEY SHOULD BE ABLE TO TURN AT LEAST ONE (1) TURN, BUT NO MORE THAN TWO (2) TURNS, CLOCKWISE BEFORE SPRING BOTTOMS OUT. F. ROPE RETURN SHOULD BE RAPID, AND WITHOUT DRAG. THE HANDLE MUST SIT IN IT'S CORRECT POSITION WITHOUT SAG. G. ALIGN FAN HOUSING WITH CHASSIS, PULLING STARTER ROPE TO ALIGN PULLEY WITH STARTER DOGS. SECURE WITH FOUR (4) SCREWS. TORQUE TO SPECIFICATION. IMPORTANT NOTE: BE SURE NOT TO PINCH SPARK PLUG WIRE. 15. CYLINDER SHIELD ASSEMBLY A. TAKING CARE TO PROPERLY ALIGN CYLINDER SHIELD, ASSEMBLE CYLINDER SHIELD TO CHASSIS USING THREE (3) SCREWS. TORQUE TO SPECIFICATION. (FIGURE AB) B. ON LOW EMISSION ENGINES ONLY. SECURE 3M REFLECTIVE TAPE ON INSIDE OF CYLINDER SHIELD AS SHOWN: ENSURE REFLECTIVE TAPE HAS BEEN FULLY PRESSED INTO POSITION ON ENTIRE SURFACE AREA WHERE THE 3M REFLECTIVE TAPE IS SECURED, MUST BE CLEAN. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 23. FRONT AND REAR HA NDLE ASSEMBLY-AV ONLY NOTE: POWERHEAD PICTURE MAY VARY DEPENDING ON MODEL. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 24. FRONT AND REAR HANDLE ASSEMBLY - AV ONLY-CONTINUED ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION FRONT HANDLE FRONT SPRING ASSEMBLY REAR SPRING SCREW-REAR SPRING REAR HANDLE REAR BOTTOM SPRING SCREW-REAR BOTTOM SPRING SCREW-FRONT/REAR HANDLE THROTTLE TRIGGER THROTTLE LOCKOUT REAR HANDLE COVER SCREW-COVER/SPRING/REAR HANDLE SCREW-COVER/REAR HANDLE SCREW-REAR TOP SPRING A. QTY 1 1 1 1 1 1 1 2 1 1 1 1 2 1 C0MMENTS M5.28-1.8 X 16 MM PLASTITE #10-14 X 19 MM PLASTITE #10-14 X 14 MM PLASTITE M5.28 X 16 MM PLASTITE #10-14 X 27 MM PLASTITE POSITION FRONT HANDLE ON SAW AND INSTALL AV SPRING ASSEMBLY TO FRONT HANDLE, AND BOTTOM OF CHASSIS WITH TWO (2) SCREWS. TORQUE TO SPECIFICATION. NOTE: MACHINE SCREW GOES INTO HANDLE. B. ATTACH LOWER, AND UPPER ISOLATOR SPRING TO HANDLE ASSEMBLY WITH SCREWS (#7& #14). C. INSTALL REAR AV SPRING (#5) IN CHASSIS POCKET WITH SCREW (#4). TORQUE TO SPECIFICATION. D. INSTALL AV SPRING (#6) NOTE: 1/8" HEX DRIVER REQUIRED. E. ASSEMBLE FRONT AND REAR HANDLES TOGETHER USING TWO (2) SCREWS (#8). TORQUE TO SPECIFICATION. F. PRESS THROTTLE CABLE ANCHOR INTO POCKET IN REAR HANDLE. G. DROP BARREL END OF CABLE INTO POCKET IN REAR HANDLE. H. SLIDE TRIGGER OVER SCREW BOSS WHILE ENSURING THAT THE THROTTLE CABLE LAYS ON TOP OF THE SEMI-CIRCULAR BOSS ON THE UPPER REAR PORTION OF THE TRIGGER. I. INSERT THROTTLE LOCKOUT CATCH THROUGH SLOT IN TRIGGER WHILE COMPRESSING THE THIN SPRING ARM TO ENSURE THAT THE SPRING FINGER RIDES ON TOP OF THE RIB IN THE TRIGGER. DROP PIN BOSS AT THE REAR OF THE LOCKOUT INTO THE POCKET IN THE REAR HANDLE. J. ASSEMBLE REAR HANDLE COVER TO REAR HANDLE (FIGURE AD). ALIGN THROTTLE LOCKOUT BOSS, AND SCREW BOSSES WITH POCKETS IN REAR HANDLE COVER. SCREW TOGETHER WITH THREE (3) SCREWS. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 NOTE: ENSURE REAR AV SPRING (#3) IS POSITIONED SO THAT THE BOTTOM REAR HANDLE COVER SCREW (#12) GOES THROUGH THE SPRING HOOK, AND ASSEMBLES TO THE REAR HANDLE , AND REAR HANDLE COVER. 20. FRONT AND REAR HANDLE ASSEMBLY - NON -AV ONLY - CONTINUED 3 A. POSITION HANDLE BAR, (#4) ON SAW (#1) USING SCREWS (2-#2 AND 2-#3). TORQUE TO SPECIFICATION. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 25. CLUTCH ASSEMBLY AND CHAIN CATCHER A. INSTALL THRUST WASHER (#1) ONTO CRANKSHAFT. B. INSTALL CLUTCH DRUM ASSEMBLY (#2) ONTO CRANKSHAFT. C. PLACE CLUTCH WASHER (#3) INSIDE CLUTCH DRUM, AND THREAD CLUTCH ASSEMBLY (#4) ONTO CRANKSHAFT. TORQUE TO SPECIFICATION. NOTE: CLUTCH IS LEFT HAND THREAD. D. INSTALL CHAIN CATCHER (#5) WITH SCREW (#6) IN CHASSIS POCKET. TORQUE TO SPECIFICATION. E. INSTALL BAR ADJUSTMENT PIN, SCREW, AND RETAINER INTO CLUTCH COVER (FIGURE S). ADJUST PIN MUST BE POSITIONED ABOVE THE CENTER LINE OF THE SCREW. (NOTE: DOES NOT APPLY ON UNITS WITH INTEGRAL BAR ADJUST SYSTEM OR TOOLESS ADJUST) IMPORTANT NOTE: RETAINER MUST BE ORIENTED AS SHOWN IN FIGURE AI. F. BAR CLAMP, BAR CLAMP NUTS, AND TORQUE TO SPECIFICATION. www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 26. INSTALL BAR ADJUSTMENT PIN, SCREW, AND RETAINER INTO CLUTCH COVER. ADJUST PIN MUST BE POSITIONED ABOVE THE CENTER LINE OF THE SCREW. IMPORTANT NOTE: RETAINER MUST BE ORIENTED AS SHOWN IN FIGURE. (FIGURE S ) www.mymowerparts.com For Discount Poulan Poulan Pro Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com
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