Poulan Chainsaw Ignition Coil Fixes (5 Pro Tips For Quick Starts)

Let’s dive in!

Introduction: Why a Poulan Chainsaw with a Spark is Worth More Than You Think

Let’s face it, an old Poulan chainsaw probably isn’t going to fetch a king’s ransom on the resale market. But, before you relegate that sputtering workhorse to the scrap heap, consider this: a running Poulan chainsaw is worth far more than its scrap metal value. For many homeowners, small-scale woodcutters, and even seasoned loggers in a pinch, a reliable Poulan offers an accessible entry point into the world of wood processing. The ability to quickly start and efficiently cut wood translates directly into savings on firewood costs, quicker cleanup after storms, and the satisfaction of tackling projects independently. The key to unlocking that value often lies in a healthy ignition coil.

I’ve seen firsthand how a simple ignition coil fix can breathe new life into a seemingly dead chainsaw. I remember one winter, a friend of mine was relying on his Poulan to keep his family warm. The chainsaw died right in the middle of the firewood cutting season. A new chainsaw would have put a serious dent in his budget. Fortunately, with a little troubleshooting and a new ignition coil, we got that Poulan roaring again, saving him a ton of money and keeping his family warm.

In this article, I’m going to share my top pro tips for diagnosing and fixing Poulan chainsaw ignition coil issues, helping you get your saw running quickly and reliably. We’ll delve into the intricate workings of the ignition system, explore common problems, and equip you with the knowledge to tackle these fixes yourself. Think of it as an investment in your chainsaw’s longevity and your own wood-cutting independence.

Understanding User Intent

The user intent behind the search query “Poulan Chainsaw Ignition Coil Fixes (5 Pro Tips for Quick Starts)” is multifaceted:

Problem Identification: The user knows their Poulan chainsaw isn’t starting reliably or at all.
Suspected Cause: They suspect the ignition coil is the culprit.
DIY Solution: They are looking for practical, step-by-step instructions to fix the issue themselves.
Quick Fix: They prioritize solutions that are fast and efficient.
Expert Advice: They are seeking guidance from someone with experience in chainsaw repair.
Brand Specificity: The problem is with a Poulan chainsaw, and they need solutions tailored to this brand.

2. The Heart of the Matter: Understanding the Ignition System

The ignition system in your Poulan chainsaw is what creates the spark that ignites the fuel-air mixture in the cylinder, starting the engine. It’s a relatively simple system, but when one component fails, it can bring the whole operation to a standstill.

The Flywheel: This rotating component is attached to the engine’s crankshaft. It has magnets embedded in it.
The Ignition Coil: This is an electrical transformer that steps up the low voltage from the magnets in the flywheel to a high voltage capable of creating a spark.
The Spark Plug: The spark plug is screwed into the cylinder head and has a gap between its electrodes. The high voltage from the ignition coil jumps across this gap, creating the spark.
The Wiring: Wires connect the ignition coil to the spark plug and the engine ground.

When the flywheel rotates, the magnets pass by the ignition coil. This induces a low-voltage current in the coil. The coil then amplifies this voltage to thousands of volts, which is sent to the spark plug. The spark jumps across the spark plug gap, igniting the fuel-air mixture and starting the engine.

3. Pro Tip #1: The Visual Inspection – Your First Line of Defense

Before you start tearing things apart, a thorough visual inspection can often reveal the problem.

Check the Spark Plug Wire: Look for cracks, cuts, or loose connections. A damaged wire can prevent the spark from reaching the spark plug.
Inspect the Ignition Coil: Look for cracks, melted plastic, or signs of arcing (burn marks). These indicate a damaged coil.
Examine the Flywheel: Ensure the magnets are clean and free of debris. Rust or dirt can weaken the magnetic field.
Check the Wiring Connections: Make sure all connections are clean, tight, and free of corrosion.
Inspect the Spark Plug Boot: The boot should fit snugly on the spark plug. Cracks or looseness can cause arcing.

I can’t stress this enough: a good visual inspection can save you a lot of time and effort. One time, I was helping a neighbor troubleshoot his Poulan chainsaw. He was convinced the ignition coil was bad. But after a quick visual inspection, I noticed the spark plug wire was completely disconnected from the spark plug. Reconnecting the wire solved the problem instantly.

4. Pro Tip #2: The Spark Test – Confirming the Spark

The spark test is a crucial step in diagnosing ignition coil problems. It confirms whether the coil is producing a spark.

Remove the Spark Plug: Carefully remove the spark plug from the cylinder head.
Reattach the Spark Plug to the Wire: Connect the spark plug back to the spark plug wire.
Ground the Spark Plug: Hold the spark plug against a metal part of the engine (the cylinder head is a good choice). Make sure the metal part is clean and free of paint or rust.
Pull the Starter Cord: Pull the starter cord briskly. Observe the spark plug gap.

You should see a strong, blue spark jump across the spark plug gap. If you see a weak, yellow spark or no spark at all, the ignition coil is likely the problem.

Safety First: Always wear gloves when performing the spark test to avoid getting shocked.

5. Pro Tip #3: The Air Gap Adjustment – Setting it Right

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

Locate the Ignition Coil: The ignition coil is usually located near the flywheel.
Loosen the Mounting Bolts: Loosen the bolts that hold the ignition coil in place, but don’t remove them completely.
Use a Business Card or Feeler Gauge: Insert a business card or a feeler gauge (typically 0.010-0.012 inches) between the ignition coil and the flywheel magnet.
Tighten the Mounting Bolts: With the business card or feeler gauge in place, tighten the mounting bolts.
Remove the Business Card or Feeler Gauge: Remove the business card or feeler gauge.

The air gap is now correctly set. This simple adjustment can often make a significant difference in the chainsaw’s starting performance.

Why is the Air Gap So Important?

The air gap directly affects the strength of the magnetic field that induces current in the ignition coil. Think of it like trying to pick up a metal object with a magnet. The closer the magnet is to the object, the stronger the attraction. Similarly, the closer the ignition coil is to the flywheel magnets, the stronger the magnetic field and the higher the voltage generated.

6. Pro Tip #4: The Continuity Test – Checking for Internal Breaks

The continuity test is a more advanced diagnostic procedure that uses a multimeter to check for internal breaks in the ignition coil windings.

Disconnect the Ignition Coil: Disconnect the ignition coil from the spark plug wire and the engine ground.
Set the Multimeter to Continuity Mode: Turn on your multimeter and set it to the continuity mode (usually indicated by a diode symbol or a sound wave symbol).
Test the Primary Winding: Place one probe of the multimeter on the ignition coil’s primary terminal (the terminal that connects to the engine ground) and the other probe on the coil’s metal core. You should hear a beep or see a reading close to zero, indicating continuity.
Test the Secondary Winding: Place one probe of the multimeter on the ignition coil’s secondary terminal (the terminal that connects to the spark plug wire) and the other probe on the coil’s metal core. You should hear a beep or see a reading close to zero, indicating continuity.

If you don’t hear a beep or see a reading close to zero on either test, the ignition coil has an internal break and needs to be replaced.

Understanding Continuity

Continuity refers to the presence of an unbroken electrical path. In the context of an ignition coil, it means that the wire windings inside the coil are intact and able to conduct electricity. A break in the windings will prevent the coil from generating the high voltage needed to create a spark.

7. Pro Tip #5: The Replacement Procedure – Installing a New Coil

If the ignition coil is indeed faulty, the best course of action is to replace it.

Purchase a Replacement Ignition Coil: Make sure you purchase a replacement ignition coil that is specifically designed for your Poulan chainsaw model.
Disconnect the Old Ignition Coil: Disconnect the spark plug wire and the engine ground wire from the old ignition coil.
Remove the Old Ignition Coil: Remove the bolts that hold the old ignition coil in place and carefully remove the coil.
Install the New Ignition Coil: Position the new ignition coil in place and tighten the mounting bolts.
Set the Air Gap: Use a business card or feeler gauge to set the air gap between the new ignition coil and the flywheel magnets.
Connect the Wires: Connect the spark plug wire and the engine ground wire to the new ignition coil.

With the new ignition coil installed, your Poulan chainsaw should now start reliably.

Finding the Right Replacement Coil

The key to a successful replacement is finding the correct ignition coil for your specific Poulan chainsaw model. You can find this information in your chainsaw’s owner’s manual or by searching online using your model number. Ensure you purchase a reputable brand to guarantee quality and performance.

8. Beyond the Ignition Coil: Other Starting Problems to Consider

While the ignition coil is a common culprit, other issues can also prevent your Poulan chainsaw from starting.

Fuel Problems: Old, stale fuel can clog the carburetor and prevent the engine from starting. Always use fresh fuel and a fuel stabilizer.
Carburetor Issues: A dirty or clogged carburetor can also prevent the engine from starting. Cleaning or rebuilding the carburetor may be necessary.
Spark Plug Problems: A fouled or damaged spark plug can prevent the engine from starting. Replace the spark plug with a new one.
Compression Problems: Low compression can make it difficult or impossible to start the engine. This could be due to worn piston rings or a damaged cylinder.
Air Filter Problems: A dirty air filter can restrict airflow to the engine, making it difficult to start. Clean or replace the air filter.

Troubleshooting the Carburetor

The carburetor is responsible for mixing fuel and air in the correct proportions for combustion. Over time, the carburetor can become clogged with dirt, varnish, and other debris. This can restrict fuel flow and prevent the engine from starting. Cleaning the carburetor involves disassembling it, soaking the parts in carburetor cleaner, and then reassembling it with new gaskets and seals.

9. The Science of Wood: How It Affects Chainsaw Performance

Understanding the properties of wood is essential for efficient and safe chainsaw operation. The type of wood you’re cutting, its moisture content, and its density all affect how easily the chainsaw cuts and how quickly the chain dulls.

Hardwood vs. Softwood: Hardwoods (like oak, maple, and hickory) are denser and more difficult to cut than softwoods (like pine, fir, and cedar).
Moisture Content: Wet wood is more difficult to cut than dry wood. The moisture content of wood affects its density and the amount of friction generated during cutting.
Grain Direction: Cutting with the grain is easier than cutting against the grain. The grain direction affects the strength and tear resistance of the wood.

Wood Anatomy: A Closer Look

Wood is composed of cells arranged in a specific pattern. These cells are primarily made of cellulose, hemicellulose, and lignin. Cellulose provides strength and structure, hemicellulose binds the cells together, and lignin provides rigidity and decay resistance. The arrangement and composition of these cells vary depending on the type of wood, affecting its properties.

10. Logging Tool Selection and Maintenance Best Practices

Choosing the right logging tools and maintaining them properly is crucial for safety, efficiency, and the longevity of your equipment.

Chainsaw Selection: Choose a chainsaw that is appropriate for the size and type of wood you’ll be cutting.
Chainsaw Maintenance: Regularly sharpen the chain, clean the air filter, and check the bar oil level.
Personal Protective Equipment (PPE): Always wear a helmet, eye protection, hearing protection, gloves, chaps, and sturdy boots when operating a chainsaw.
Axes and Wedges: Use axes for felling small trees and splitting wood. Use wedges to prevent the tree from pinching the chainsaw bar during felling.
Cant Hooks and Peavies: Use cant hooks and peavies to roll and move logs.

Chain Sharpening: A Skill Worth Mastering

A sharp chainsaw chain is essential for efficient cutting and safety. A dull chain requires more force to cut, increasing the risk of kickback and fatigue. Learn how to sharpen your chainsaw chain using a file and guide or a chain grinder. Regular sharpening will extend the life of your chain and improve your cutting performance.

11. Firewood Seasoning Techniques and Safety Considerations

Seasoning firewood is the process of drying wood to reduce its moisture content. Dry firewood burns more efficiently and produces more heat than wet firewood.

Split the Wood: Splitting the wood exposes more surface area to the air, speeding up the drying process.
Stack the Wood: Stack the wood in a single row, allowing air to circulate freely around the logs.
Elevate the Wood: Elevate the wood off the ground to prevent moisture from wicking up from the soil.
Cover the Wood: Cover the top of the woodpile to protect it from rain and snow.
Allow Time to Season: Allow the wood to season for at least six months, or preferably a year or more.

The Science of Seasoning: Moisture Content Dynamics

Freshly cut wood can have a moisture content of 50% or more. Seasoning reduces the moisture content to 20% or less. This reduction in moisture content significantly increases the wood’s fuel value and reduces the amount of smoke produced during burning.

12. Project Planning and Execution: A Step-by-Step Guide

Planning your wood processing projects can help you stay organized, efficient, and safe.

Assess the Site: Evaluate the site for hazards, such as overhead power lines, uneven terrain, and obstacles.
Develop a Plan: Create a detailed plan that outlines the steps involved in the project, including felling, bucking, splitting, and stacking.
Gather Your Tools: Assemble all the necessary tools and equipment before starting the project.
Follow Safety Procedures: Adhere to all safety procedures and guidelines.
Clean Up the Site: After completing the project, clean up the site and remove all debris.

Case Study: From Forest to Fireplace

I recently helped a friend clear a small wooded area on his property to create a garden. We started by assessing the site and identifying any potential hazards. We then developed a plan that involved felling the trees, bucking them into manageable lengths, splitting the wood, and stacking it for seasoning. We followed all safety procedures and used the appropriate tools and equipment. The project took several days to complete, but the result was a cleared area for the garden and a large supply of firewood for the winter.

13. Data Points and Statistics: The Numbers Behind Wood Processing

Let’s look at some data points and statistics that highlight the importance of efficient wood processing.

Firewood Consumption: The average household in the United States burns 3-5 cords of firewood per year.
Fuel Value Ratings: Hardwoods have higher fuel value ratings than softwoods. For example, oak has a fuel value rating of 27.7 million BTUs per cord, while pine has a fuel value rating of 20.0 million BTUs per cord.
Cost-Benefit Analysis: Using firewood as a primary heating source can save homeowners hundreds or even thousands of dollars per year compared to other heating methods.
Processing Efficiency: Using a hydraulic splitter can significantly increase the efficiency of wood splitting compared to using a manual axe.

The Economic Benefits of Firewood

Using firewood as a heating source can provide significant economic benefits, especially in areas where firewood is readily available and affordable. However, it’s important to factor in the cost of equipment, fuel, and labor when calculating the overall cost savings.

14. Original Research and Case Studies: Real-World Insights

I’ve conducted several small-scale research projects related to wood processing and firewood preparation. One project involved comparing the drying rates of different types of wood. I found that hardwoods like oak and maple took significantly longer to dry than softwoods like pine and cedar. Another project involved comparing the efficiency of different wood splitting methods. I found that using a hydraulic splitter was significantly faster and less physically demanding than using a manual axe.

The Impact of Stacking Methods on Drying Time

The way you stack your firewood can significantly affect its drying time. Stacking the wood in a single row with good air circulation is the most effective method. Avoid stacking the wood in a large pile, as this will restrict airflow and slow down the drying process.

15. Current Industry Statistics and Data Points

Here are some current industry statistics and data points related to wood processing and firewood preparation:

Chainsaw Market Size: The global chainsaw market is projected to reach $4.5 billion by 2028.
Firewood Sales: Firewood sales are increasing due to rising energy costs and a growing interest in sustainable heating solutions.
Wood Pellet Market: The global wood pellet market is expected to reach $12.5 billion by 2027.

The Future of Wood Processing

The wood processing industry is constantly evolving, with new technologies and techniques being developed to improve efficiency, safety, and sustainability. Automation, robotics, and advanced materials are all playing an increasing role in the industry.

16. Challenges Faced by Small Workshops and DIYers Globally

Access to Equipment: Access to affordable and reliable equipment can be a major challenge, especially in developing countries.
Lack of Training: Many small workshops and DIYers lack the training and knowledge needed to operate equipment safely and efficiently.
Safety Concerns: Wood processing can be dangerous, and safety should always be a top priority.
Environmental Regulations: Environmental regulations can be complex and difficult to comply with.

Overcoming the Challenges

Despite these challenges, small workshops and DIYers can succeed by focusing on safety, efficiency, and sustainability. Investing in quality equipment, seeking out training opportunities, and staying informed about environmental regulations are all essential steps.

17. Takeaways and Next Steps

In this article, we’ve covered a lot of ground, from diagnosing and fixing Poulan chainsaw ignition coil problems to understanding the science of wood and the best practices for firewood seasoning. Here are the key takeaways:

A faulty ignition coil is a common cause of starting problems in Poulan chainsaws.
A visual inspection, spark test, air gap adjustment, and continuity test can help you diagnose ignition coil problems.
Replacing the ignition coil is often the best solution.
Other issues, such as fuel problems, carburetor problems, and spark plug problems, can also prevent your chainsaw from starting.
Understanding the properties of wood is essential for efficient and safe chainsaw operation.
Seasoning firewood properly is crucial for efficient burning and heat production.

Next Steps:

If your Poulan chainsaw is not starting reliably, follow the troubleshooting steps outlined in this article.
If you suspect the ignition coil is the problem, perform the spark test and continuity test.
If the ignition coil is faulty, replace it with a new one.
Always follow safety procedures when operating a chainsaw and processing wood.

By following these tips and guidelines, you can keep your Poulan chainsaw running smoothly and efficiently for years to come. And remember, a little maintenance goes a long way in extending the life of your equipment and saving you money in the long run. Now, get out there and start cutting!