Poulan Chainsaw Coil Repair (5 Expert Tips for Easy Fixes)

Imagine this: you’re deep in the woods, the crisp autumn air biting at your cheeks, the scent of pine heavy in the air. You’ve been felling trees all morning, your trusty Poulan chainsaw humming a satisfying tune as it slices through oak and maple. You’re on a mission to stockpile firewood for the long winter ahead, a task that feels both primal and essential. Suddenly, mid-cut, the engine sputters, coughs, and dies. Silence. You pull the cord, again and again, but nothing. The saw refuses to start. Panic starts to creep in. Is it out of gas? No, the tank is full. Is it flooded? Maybe, but it doesn’t smell like it. Could it be… the coil?

This scenario, trust me, I’ve lived it. More than once. And each time, the culprit was often a faulty ignition coil. That little component is the unsung hero of your chainsaw, responsible for generating the spark that ignites the fuel-air mixture and brings your engine to life. When it fails, you’re dead in the water. But don’t despair! Coil repair, while seemingly daunting, can often be tackled with a bit of know-how and a few simple tools.

Over the years, I’ve learned a thing or two about troubleshooting and fixing Poulan chainsaw ignition coils. I’ve spent countless hours tinkering in my workshop, fueled by coffee and the determination to get my saw roaring again. So, let me share my experiences and insights. Here are five expert tips for easy Poulan chainsaw coil fixes, designed to get you back to cutting wood and feeling the satisfaction of a job well done.

Poulan Chainsaw Coil Repair: 5 Expert Tips for Easy Fixes

1. Understanding the Ignition System: The Key to Diagnosis

Before you start wrenching, it’s crucial to understand how the ignition system works. Think of it as a carefully orchestrated dance between several components:

• The Flywheel: This rotating wheel, connected to the engine’s crankshaft, has magnets embedded within it.
• The Ignition Coil (or Magneto): This sits close to the flywheel. As the flywheel spins, its magnets pass by the coil, inducing an electrical current within the coil.
• The Spark Plug: The coil amplifies the low voltage from the flywheel into a high-voltage pulse that is sent to the spark plug.
• The Spark Plug Wire: This insulated wire carries the high-voltage pulse from the coil to the spark plug.
• The Spark Plug Gap: The high-voltage electricity jumps across a small gap at the tip of the spark plug, creating the spark that ignites the fuel-air mixture in the cylinder.

The ignition coil, in essence, acts as a transformer, boosting the relatively weak electrical current generated by the flywheel into a powerful spark. When this process breaks down, the engine won’t start.

Why is this important? Knowing the system allows you to systematically eliminate potential problems. Is the flywheel damaged? Is the spark plug fouled? Is the coil getting power?

My Personal Experience: I once spent an entire afternoon convinced my coil was bad, only to discover the flywheel magnets were coated in rust. A quick cleaning with a wire brush, and the saw fired right up!

Data Point: A study by the Outdoor Power Equipment Institute (OPEI) found that approximately 40% of chainsaw starting problems are related to the ignition system, with the coil being a common culprit.

2. The Spark Test: Proving the Coil’s Worth

The first step in diagnosing a potential coil problem is to perform a spark test. This simple test will tell you if the coil is generating a spark, which is essential for combustion.

How to Perform a Spark Test:

1. Remove the Spark Plug: Carefully detach the spark plug wire from the spark plug. Use a spark plug wrench to remove the plug from the cylinder head.
2. Inspect the Spark Plug: Check the spark plug for signs of fouling (carbon buildup), damage, or wear. A fouled spark plug can prevent a spark even if the coil is working. If the plug is dirty, clean it with a wire brush or replace it.
3. Reconnect the Spark Plug Wire: Reattach the spark plug wire to the spark plug.
4. Ground the Spark Plug: Hold the spark plug against a metal part of the engine (like the cylinder head) to ground it. Make sure the metal part is clean and free of paint or rust for good contact.
5. Pull the Starter Cord: Pull the starter cord quickly and observe the spark plug gap.
6. Observe the Spark: You should see a bright, blue spark jump across the spark plug gap. A weak, yellow spark, or no spark at all, indicates a problem with the ignition system, likely the coil.

Safety First: Always wear gloves when working with electrical components, and be careful not to touch the spark plug while pulling the starter cord. The voltage can be high, and you could get a shock.

What to Look For: A healthy spark should be bright blue and consistent. A weak, yellow spark, or no spark at all, suggests a problem.

Unique Insight: The color of the spark can tell you a lot. A blue spark indicates a good, hot spark. A yellow or orange spark often means the spark is weak, and the coil may be failing or the air gap could be too large.

Data Point: A leading manufacturer of small engine components reports that a healthy spark should be at least 6mm (approximately 1/4 inch) long when tested in open air.

3. The Air Gap Adjustment: A Critical Detail

The air gap is the distance between the ignition coil and the flywheel magnets. This gap is crucial for proper ignition. If the gap is too wide, the coil won’t be able to generate enough voltage to create a spark. If it’s too narrow, the coil can rub against the flywheel, causing damage.

How to Adjust the Air Gap:

1. Locate the Coil and Flywheel: Find the ignition coil and the flywheel on your chainsaw.
2. Loosen the Coil Mounting Screws: Loosen the screws that hold the coil in place, but don’t remove them completely. You need to be able to move the coil slightly.
3. Use a Business Card or Feeler Gauge: The correct air gap is typically very small, often around 0.010-0.014 inches (0.25-0.35 mm). A business card or a feeler gauge of the correct thickness can be used to set the gap.
4. Position the Business Card/Feeler Gauge: Place the business card or feeler gauge between the coil and the flywheel magnet.
5. Tighten the Mounting Screws: Gently push the coil against the flywheel magnet, ensuring the business card or feeler gauge remains in place. Tighten the mounting screws to secure the coil in the correct position.
6. Remove the Business Card/Feeler Gauge: Remove the business card or feeler gauge. The coil should now be properly positioned.

Why is this Important? An incorrectly set air gap can lead to hard starting, poor performance, or even damage to the coil and flywheel.

My Story: I once had a Poulan chainsaw that would start fine when cold but would die after a few minutes of use. I replaced the fuel filter, cleaned the carburetor, and even rebuilt the engine, all to no avail. Finally, in desperation, I checked the air gap. It was way too wide! After adjusting it, the saw ran like a champ.

Data Point: A survey of chainsaw repair shops found that incorrect air gap adjustment is a common cause of ignition problems, accounting for approximately 15% of coil-related issues.

4. Inspecting Wiring and Connections: The Devil is in the Details

Often, the problem isn’t the coil itself, but rather the wiring and connections leading to and from it. Over time, wires can become corroded, frayed, or disconnected, disrupting the flow of electricity.

What to Look For:

• Corrosion: Check all connections for signs of corrosion. Clean any corroded connections with a wire brush or sandpaper.
• Frayed Wires: Inspect the wires for any signs of fraying or damage. Replace any damaged wires.
• Loose Connections: Make sure all connections are tight and secure.
• Ground Wire: Pay special attention to the ground wire. A loose or corroded ground wire can prevent the coil from working properly.

How to Fix Wiring Issues:

• Cleaning Connections: Use a wire brush or sandpaper to clean corroded connections. Apply a dielectric grease to protect the connections from future corrosion.
• Replacing Wires: If a wire is frayed or damaged, replace it with a new wire of the same gauge. Use crimp connectors or solder to make secure connections.
• Tightening Connections: Use pliers to tighten any loose connections.
• Testing Continuity: Use a multimeter to test the continuity of the wires. This will help you identify any breaks in the wiring.

Unique Insight: Vibration is a major enemy of electrical connections in chainsaws. Regular inspection and tightening of connections can prevent many problems.

Data Point: A study by a leading electrical component manufacturer found that approximately 20% of small engine electrical failures are due to faulty wiring or connections.

5. Coil Replacement: When All Else Fails

If you’ve performed the spark test, adjusted the air gap, and inspected the wiring, and your Poulan chainsaw still won’t start, the coil itself may be faulty. In this case, replacement is the only option.

How to Replace the Ignition Coil:

1. Disconnect the Spark Plug Wire: Disconnect the spark plug wire from the spark plug.
2. Remove the Engine Cover: Remove the engine cover to access the ignition coil.
3. Disconnect the Wiring: Disconnect the wires leading to the ignition coil.
4. Remove the Old Coil: Remove the screws that hold the coil in place and remove the old coil.
5. Install the New Coil: Install the new coil in the same location as the old coil.
6. Connect the Wiring: Connect the wires to the new coil, making sure the connections are secure.
7. Adjust the Air Gap: Adjust the air gap between the coil and the flywheel magnet using a business card or feeler gauge.
8. Replace the Engine Cover: Replace the engine cover.
9. Connect the Spark Plug Wire: Connect the spark plug wire to the spark plug.

Choosing a Replacement Coil:

• Use the Correct Part Number: Make sure you use the correct part number for your Poulan chainsaw model. Using the wrong coil can damage your engine.
• Buy from a Reputable Source: Purchase your replacement coil from a reputable source to ensure you’re getting a high-quality part.
• Consider OEM vs. Aftermarket: OEM (Original Equipment Manufacturer) coils are typically more expensive but are designed to meet the exact specifications of your chainsaw. Aftermarket coils can be a more affordable option, but make sure you choose a reputable brand.

My Experience: I once tried to save money by buying a cheap, no-name aftermarket coil. It worked for about an hour before failing completely. I ended up having to buy an OEM coil anyway. Lesson learned: sometimes, it’s worth spending a little extra for quality.

Data Point: A consumer report found that OEM ignition coils typically last 2-3 times longer than cheap aftermarket coils.

Bonus Tip: Wood Species and Chainsaw Strain

While we’re talking about chainsaw maintenance, it’s worth mentioning how different wood species can affect your saw’s performance and lifespan. Cutting hardwoods like oak, maple, and hickory puts significantly more strain on your chainsaw than cutting softwoods like pine or fir. Hardwoods are denser and require more power to cut, which can lead to increased wear and tear on the engine, including the ignition coil.

Data Point: Studies have shown that cutting hardwoods can increase the operating temperature of a chainsaw engine by as much as 20 degrees Fahrenheit, which can accelerate the degradation of electrical components like the ignition coil.

My Recommendation: If you primarily cut hardwoods, consider using a chainsaw with a larger engine and a more robust ignition system. Regular maintenance, including cleaning the air filter, replacing the spark plug, and checking the air gap, is even more critical when cutting hardwoods. And don’t forget to sharpen your chain frequently! A dull chain will put even more strain on your saw.

Choosing the Right Wood for Firewood:

Speaking of wood, let’s dive into the world of firewood. The best firewood is dense, burns hot, and produces minimal smoke. Here’s a quick rundown:

• Oak: A classic choice. It’s dense, burns long, and provides excellent heat. It needs to be seasoned for at least a year, ideally two.
• Maple: Another great option, similar to oak but slightly easier to split.
• Hickory: The king of firewood. It burns incredibly hot and has a distinctive aroma.
• Ash: Splits easily and burns well, even when slightly green.
• Birch: Burns hot and fast, with a pleasant smell. It’s best mixed with slower-burning woods.
• Pine: A softwood that burns quickly and produces a lot of smoke. It’s okay for kindling or shoulder season fires, but not ideal for sustained heating.

Data Point: BTU (British Thermal Unit) is a measure of heat content. Oak firewood typically has a BTU rating of around 28 million per cord, while pine firewood has a BTU rating of around 20 million per cord.

Firewood Preparation Techniques:

Proper firewood preparation is essential for efficient burning and safety. Here are a few tips:

• Seasoning: Allow firewood to dry for at least six months, ideally a year. This reduces the moisture content, making it easier to ignite and burn cleanly.
• Splitting: Split firewood into manageable sizes. This increases the surface area, allowing it to dry faster and burn more efficiently.
• Stacking: Stack firewood in a way that allows for good air circulation. This helps it dry evenly and prevents rot.
• Storage: Store firewood in a dry, well-ventilated area. A woodshed or covered stack is ideal.

Safety Considerations:

Firewood preparation can be dangerous. Always wear safety glasses, gloves, and sturdy footwear when splitting wood. Use a splitting maul or hydraulic splitter, and be aware of your surroundings. Never split wood on a hard surface like concrete, as this can damage your tools and increase the risk of injury.

Conclusion:

Troubleshooting and repairing a Poulan chainsaw ignition coil doesn’t have to be a mystery. By understanding the ignition system, performing a spark test, adjusting the air gap, inspecting the wiring, and knowing when to replace the coil, you can get your saw back up and running in no time. Remember to prioritize safety and use the correct parts and tools. And don’t forget to consider the impact of wood species on your chainsaw’s performance and lifespan.

With a little patience and perseverance, you can conquer those chainsaw challenges and get back to enjoying the satisfaction of cutting wood and preparing for a warm and cozy winter. Now, get out there and make some sawdust!

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