How to Change the Chain Drive on a Poulan Chain Saw
- 1). Turn off the Poulan chainsaw, and release the chain brake by pulling back on the chain brake lever. The chain brake is the plastic bar located on the top of the body and is between the bar and the throttle. With a gloved hand, spin the chain to ensure the chain brake is off.
- 2). Use a wrench to loosen the bar cover's retaining nuts, which are located opposite to the muffler. Remove the faceplate cover. Loosen the bar's tensioner screw to release the chain from the bar. Turn the screw counterclockwise to release tension. Take off the chain and bar, and set them aside.
- 3). Pull the spark plug's wire connector from the spark plug. Use a piece of rope or the starter's pull cord to lock the crank. Push the rope or cord into the spark plug's hole, but leave enough to pull it out again. This is essential because it keeps the driveshaft stationery and allows you to remove the clutch assembly.
- 4). Remove the clutch, which is located underneath the clutch plate and is butterfly-shaped with a circular metal spring inside. Most Poulan saws have an inboard clutch drum that uses a locking bolt to attach it to the engine.
- 5). Release the bolt in the clutch's center by turning it clockwise with the screwdriver. You may need to use the mallet to tap the nut free. Unscrew it the rest of the way by hand. If your Poulan has an outboard clutch drum, remove the E-clip to pull off the clutch assembly.
- 6). Pull off the sprocket, which is circular and attached to a six-sided star or asterisk, which is part of the clutch drum. The sprocket and clutch drum should pull off easily. Throw away the old sprocket. If the clutch drum is also heavily chipped and worn, replace that as well.
- 7). Put the new sprocket onto the clutch drum in the same place as the old one. Put the clutch drum, with the sprocket in place, back inside the engine housing. Attach the clutch back on top of the clutch drum and sprocket. Turn the clutch's bolt counterclockwise to attach all of them to the engine. Re-fit the clutch plate over the clutch. Take out the rope and cord from the spark plug's hole.
- 8). Re-attach the bar and chain to your Poulan chainsaw by reversing step 2.
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