Poulan Chainsaw Won't Stay Running (5 Pro Fixes For Smooth Cuts)

I’ve always appreciated the simple design of Poulan chainsaws. They’re built for straightforward tasks, and usually, maintaining them is a breeze. A quick wipe-down after use, keeping the chain sharp, and ensuring the air filter is clean generally keeps them humming. But, like any hardworking tool, a Poulan chainsaw can sometimes throw a wrench in the works and refuse to stay running. I’ve wrestled with this issue countless times, especially during peak firewood season when the pressure is on to get those logs split and stacked. It’s incredibly frustrating to have a chainsaw sputter and die mid-cut. Over the years, I’ve developed a methodical approach to diagnosing and fixing this common problem. This guide shares the five most common reasons your Poulan chainsaw won’t stay running, along with pro-level fixes to get you back to cutting smoothly.

Poulan Chainsaw Won’t Stay Running: 5 Pro Fixes for Smooth Cuts

The rhythmic roar of a chainsaw is music to the ears of anyone involved in wood processing, logging, or firewood preparation. Whether you’re felling trees in the forest, bucking logs into manageable lengths, or simply preparing firewood for a cozy winter, a reliable chainsaw is your best friend. But what happens when that trusty Poulan chainsaw, known for its affordability and ease of use, suddenly refuses to stay running? The frustration is palpable. The good news is that most of these issues are easily diagnosed and fixed with a bit of know-how and a few basic tools.

Understanding the Importance of a Well-Running Chainsaw

Before diving into the fixes, it’s crucial to understand why a properly functioning chainsaw is paramount.

Efficiency: A chainsaw that runs smoothly cuts faster and with less effort, saving you time and energy.
Safety: A sputtering or stalling chainsaw can be dangerous, increasing the risk of kickback or loss of control.
Tool Longevity: Addressing issues promptly prevents further damage and extends the life of your chainsaw.

Key Terms and Concepts

Let’s clarify some essential terms for those new to chainsaw maintenance:

Green Wood vs. Seasoned Wood: Green wood is freshly cut and has a high moisture content, making it heavier and harder to cut. Seasoned wood has been air-dried for months or even years, reducing its moisture content and making it lighter and easier to split and burn. The moisture content of green wood can be 50% or higher, while seasoned wood ideally has a moisture content of 20% or less.
Carburetor: The carburetor mixes air and fuel in the correct proportions to create a combustible mixture for the engine.
Air Filter: The air filter prevents dirt and debris from entering the engine, ensuring clean air intake.
Fuel Filter: The fuel filter prevents contaminants from entering the carburetor, ensuring a clean fuel supply.
Spark Plug: The spark plug ignites the air-fuel mixture in the engine cylinder, initiating the combustion process.
Chain Brake: A safety mechanism that stops the chain immediately in case of kickback.
Kickback: A sudden and forceful backward movement of the chainsaw bar, often caused by the tip of the bar contacting a solid object.

Fix 1: Clogged or Dirty Air Filter

The air filter is the first line of defense against dirt and debris entering your chainsaw’s engine. A clogged air filter restricts airflow, leading to a lean fuel mixture (too much air, not enough fuel) and causing the engine to stall. I’ve seen this happen countless times, especially when cutting dry, dusty wood.

Symptoms of a Clogged Air Filter:

The chainsaw starts but stalls shortly after.
Reduced engine power.
Black smoke coming from the exhaust.
Difficulty starting.

Step-by-Step Cleaning Process:

Safety First: Ensure the chainsaw is turned off and the chain brake is engaged. Allow the engine to cool completely.
Locate the Air Filter: On Poulan chainsaws, the air filter is typically located under a cover on top or on the side of the engine. Refer to your owner’s manual for the exact location.
Remove the Cover: Use a screwdriver or the provided tool to remove the air filter cover.
Inspect the Air Filter: Carefully remove the air filter and examine it for dirt, dust, and debris.
Cleaning Options:
- Blowing: Use compressed air to blow out the dirt from the inside out. Wear safety glasses to protect your eyes.
- Washing: Wash the air filter in warm, soapy water. Rinse thoroughly and allow it to dry completely before reinstalling. Note: Not all air filters are washable. Check your owner’s manual.
- Replacement: If the air filter is heavily soiled or damaged, replace it with a new one.
Reinstall the Air Filter: Carefully reinstall the cleaned or new air filter into its housing.
Replace the Cover: Secure the air filter cover.
Test the Chainsaw: Start the chainsaw and see if it runs smoothly.

Pro Tip:

I always keep a spare air filter on hand, especially during heavy use periods. This allows me to quickly swap out a dirty filter and keep working without interruption.
Consider using a pre-filter, which is a foam sleeve that fits over the air filter, to extend the life of the main filter.
For extremely dirty conditions, consider cleaning the air filter daily.

Case Study:

I once worked on a large firewood project where we were cutting seasoned oak logs. The wood was extremely dry, and the air was thick with sawdust. My Poulan chainsaw started stalling every few minutes. After checking the usual suspects (fuel, spark plug), I realized the air filter was completely clogged. I cleaned it thoroughly, and the chainsaw ran like new again. This experience reinforced the importance of regular air filter maintenance.

Fix 2: Dirty or Clogged Fuel Filter

The fuel filter prevents dirt and debris from entering the carburetor, ensuring a clean fuel supply. A clogged fuel filter restricts fuel flow, leading to a lean fuel mixture and causing the engine to stall, especially under load.

Symptoms of a Clogged Fuel Filter:

The chainsaw starts but stalls, particularly when accelerating.
Reduced engine power.
Difficulty starting.
Inconsistent engine performance.

Step-by-Step Replacement Process:

Safety First: Ensure the chainsaw is turned off and the chain brake is engaged. Allow the engine to cool completely.
Locate the Fuel Filter: The fuel filter is located inside the fuel tank, attached to the end of the fuel line.
Access the Fuel Filter:
- Remove the fuel cap.
- Use a clean wire (like a bent coat hanger) with a small hook on the end to fish out the fuel line and filter from the tank. Be gentle to avoid damaging the fuel line.
Disconnect the Old Filter: Carefully disconnect the old fuel filter from the fuel line.
Install the New Filter: Connect the new fuel filter to the fuel line. Ensure it’s securely attached.
Reinstall the Filter: Carefully lower the fuel filter and fuel line back into the fuel tank.
Replace the Fuel Cap: Secure the fuel cap.
Test the Chainsaw: Start the chainsaw and see if it runs smoothly.

Pro Tip:

I recommend replacing the fuel filter annually, or more frequently if you use your chainsaw heavily.
When replacing the fuel filter, inspect the fuel lines for cracks or damage. Replace them if necessary.
Use fresh, high-quality fuel mixed with the correct ratio of oil. I prefer using ethanol-free fuel whenever possible, as ethanol can damage small engine components.

Case Study:

I once purchased a used Poulan chainsaw that ran poorly. It would start, but stall almost immediately. After replacing the spark plug and cleaning the air filter, I decided to check the fuel filter. It was completely clogged with gunk. Replacing the fuel filter made a world of difference, and the chainsaw ran like a champ. This experience taught me the importance of checking the fuel filter, especially when dealing with used equipment.

Fix 3: Faulty Spark Plug

The spark plug ignites the air-fuel mixture in the engine cylinder, initiating the combustion process. A faulty spark plug can cause a weak spark or no spark at all, leading to starting problems, stalling, and poor engine performance.

Symptoms of a Faulty Spark Plug:

Difficulty starting.
The chainsaw starts but stalls shortly after.
Reduced engine power.
Rough idling.
Wet or fouled spark plug.

Step-by-Step Replacement Process:

Safety First: Ensure the chainsaw is turned off and the chain brake is engaged. Allow the engine to cool completely.
Locate the Spark Plug: The spark plug is typically located on the side of the engine, near the cylinder head.
Remove the Spark Plug Boot: Gently pull the spark plug boot (the rubber cap) off the spark plug.
Remove the Spark Plug: Use a spark plug wrench (or a deep socket wrench) to loosen and remove the spark plug.
Inspect the Spark Plug: Examine the spark plug for signs of wear, damage, or fouling (carbon buildup).
- Normal: A tan or light brown color indicates a healthy engine.
- Black and Sooty: Indicates a rich fuel mixture (too much fuel).
- Oily: Indicates oil entering the combustion chamber.
- White or Light Gray: Indicates a lean fuel mixture (too much air).
Replace the Spark Plug: Install a new spark plug of the correct type (refer to your owner’s manual for the correct spark plug number).
Gap the Spark Plug: Use a spark plug gapping tool to ensure the gap between the center electrode and the ground electrode is correct (refer to your owner’s manual for the correct gap setting). Typically, this gap is around 0.025 – 0.030 inches.
Tighten the Spark Plug: Tighten the spark plug using the spark plug wrench. Do not overtighten.
Reinstall the Spark Plug Boot: Push the spark plug boot back onto the spark plug.
Test the Chainsaw: Start the chainsaw and see if it runs smoothly.

Pro Tip:

I recommend replacing the spark plug annually, or more frequently if you use your chainsaw heavily.
Keep a spare spark plug on hand.
When installing a new spark plug, apply a small amount of anti-seize compound to the threads to prevent it from seizing in the cylinder head.
If the spark plug is repeatedly fouling, it may indicate a more serious engine problem.

Case Study:

I was helping a friend clear some brush on his property when his Poulan chainsaw suddenly died. We tried everything to get it started, but nothing worked. Finally, I decided to check the spark plug. It was completely fouled with carbon buildup. After replacing the spark plug, the chainsaw started immediately and ran perfectly. This experience highlighted the importance of a clean and properly functioning spark plug.

Fix 4: Carburetor Issues

The carburetor is responsible for mixing air and fuel in the correct proportions to create a combustible mixture for the engine. If the carburetor is dirty, clogged, or improperly adjusted, it can cause the engine to stall, run poorly, or not start at all. This is often the trickiest issue to diagnose and fix, but with patience and the right tools, it’s manageable.

Symptoms of Carburetor Problems:

Difficulty starting.
The chainsaw starts but stalls shortly after.
Rough idling.
Reduced engine power.
Black smoke coming from the exhaust (rich fuel mixture).
White or light gray spark plug (lean fuel mixture).

Step-by-Step Cleaning and Adjustment Process:

Important Note: Carburetor adjustment can be complex. If you’re not comfortable with this process, it’s best to take your chainsaw to a qualified repair shop.

Safety First: Ensure the chainsaw is turned off and the chain brake is engaged. Allow the engine to cool completely.
Locate the Carburetor: The carburetor is typically located behind the air filter.
Remove the Air Filter and Cover: Remove the air filter and any covers that are blocking access to the carburetor.
Inspect the Carburetor: Visually inspect the carburetor for dirt, debris, and damage.
Cleaning the Carburetor:
- Carburetor Cleaner: Spray carburetor cleaner into the carburetor’s intake and throttle bore. Allow it to soak for a few minutes, then wipe away any excess cleaner.
- Disassembly (Advanced): For a more thorough cleaning, you can disassemble the carburetor. Note: This requires some mechanical skill and knowledge of carburetor components.
  - Carefully remove the carburetor from the engine.
  - Disassemble the carburetor, taking note of the location of each part.
  - Clean each part with carburetor cleaner and a soft brush. Pay particular attention to the jets and passages.
  - Reassemble the carburetor, ensuring all parts are properly seated.
Carburetor Adjustment:
- Locate the Adjustment Screws: Most Poulan chainsaws have two or three adjustment screws on the carburetor, typically labeled “H” (high-speed), “L” (low-speed), and sometimes “T” (idle speed).
- Initial Settings: Refer to your owner’s manual for the recommended initial settings for the adjustment screws. As a general starting point, turn both the “H” and “L” screws clockwise until they are lightly seated, then back them out 1 1/2 turns.
- Starting the Chainsaw: Start the chainsaw and allow it to warm up for a few minutes.
- Low-Speed Adjustment (L): Adjust the “L” screw until the engine idles smoothly without stalling. If the engine idles too fast, turn the “L” screw clockwise. If the engine stalls, turn the “L” screw counterclockwise.
- High-Speed Adjustment (H): Caution: Improper high-speed adjustment can damage the engine. Use a tachometer to monitor the engine speed. Adjust the “H” screw while the chainsaw is cutting wood. The goal is to achieve maximum power without exceeding the engine’s maximum RPM (revolutions per minute). Refer to your owner’s manual for the maximum RPM. If the engine bogs down under load, turn the “H” screw counterclockwise. If the engine screams or hesitates, turn the “H” screw clockwise.
- Idle Speed Adjustment (T): Adjust the “T” screw until the chain stops moving at idle. If the chain is moving, turn the “T” screw clockwise. If the engine stalls, turn the “T” screw counterclockwise.
Reinstall the Air Filter and Cover: Reinstall the air filter and any covers that were removed.
Test the Chainsaw: Start the chainsaw and see if it runs smoothly.

Pro Tip:

Before disassembling the carburetor, take pictures or make a diagram of the parts and their locations. This will make reassembly much easier.
Use a carburetor rebuild kit to replace worn or damaged parts.
If you’re not comfortable adjusting the carburetor yourself, take your chainsaw to a qualified repair shop.
A slightly rich fuel mixture (slightly more fuel than air) is generally better than a lean fuel mixture, as it helps to keep the engine cool and lubricated.

Case Study:

I had a Poulan chainsaw that would start and idle fine, but would stall as soon as I tried to cut anything. I suspected a carburetor problem. I carefully disassembled the carburetor, cleaned all the parts, and reassembled it. After adjusting the “H” and “L” screws, the chainsaw ran perfectly. This experience taught me the importance of patience and attention to detail when working on carburetors. It’s also worth noting that sometimes the internal fuel lines within the tank can crack, leading to air being sucked into the system. This can mimic carburetor issues, so it’s worth inspecting those lines as well.

Fix 5: Exhaust System Blockage (Spark Arrestor)

The exhaust system allows exhaust gases to escape from the engine. A blocked exhaust system restricts the flow of exhaust gases, leading to reduced engine power, overheating, and stalling. The spark arrestor, a screen designed to prevent sparks from escaping the exhaust, is a common culprit for blockages.

Symptoms of an Exhaust System Blockage:

Reduced engine power.
Overheating.
The chainsaw starts but stalls shortly after.
Black smoke coming from the exhaust.
Difficulty starting.

Step-by-Step Cleaning Process:

Safety First: Ensure the chainsaw is turned off and the chain brake is engaged. Allow the engine to cool completely.
Locate the Spark Arrestor: The spark arrestor is typically located on the muffler, which is attached to the exhaust port on the engine.
Remove the Spark Arrestor: Remove the screws or bolts that hold the spark arrestor in place.
Inspect the Spark Arrestor: Examine the spark arrestor screen for carbon buildup or other debris.
Cleaning Options:
- Wire Brush: Use a wire brush to scrub away the carbon buildup from the spark arrestor screen.
- Carburetor Cleaner: Spray carburetor cleaner onto the spark arrestor screen and allow it to soak for a few minutes, then scrub it with a wire brush.
- Burning: In some cases, you can burn off the carbon buildup by heating the spark arrestor screen with a propane torch. Note: Use caution when using a torch and avoid overheating the screen.
Reinstall the Spark Arrestor: Reinstall the spark arrestor screen and secure it with the screws or bolts.
Test the Chainsaw: Start the chainsaw and see if it runs smoothly.

Pro Tip:

I recommend cleaning the spark arrestor screen every 25 hours of use, or more frequently if you use your chainsaw heavily.
If the spark arrestor screen is damaged or corroded, replace it with a new one.
Running the chainsaw with a blocked spark arrestor can damage the engine.

Case Study:

I was cutting firewood with a group of friends when one of their Poulan chainsaws started losing power and eventually stalled. We checked the usual suspects (fuel, spark plug, air filter), but everything seemed fine. Finally, I decided to check the spark arrestor. It was completely clogged with carbon buildup. After cleaning the spark arrestor, the chainsaw ran like new again. This experience showed me the importance of regular spark arrestor maintenance, especially when cutting dry, resinous wood.

Additional Considerations and Preventative Maintenance

Beyond these five core fixes, there are a few other factors that can contribute to a Poulan chainsaw stalling.

Fuel Mixture: Always use the correct fuel-to-oil ratio as specified in your owner’s manual. Using the wrong ratio can lead to engine damage and performance problems. Poulan chainsaws typically require a 40:1 or 50:1 fuel-to-oil ratio. I always measure carefully using a dedicated measuring container to ensure accuracy.
Fuel Quality: Use fresh, high-quality fuel. Old or stale fuel can cause starting problems and poor engine performance. Ethanol-free fuel is ideal, but if you must use fuel containing ethanol, use a fuel stabilizer to prevent it from absorbing moisture and corroding engine components.
Chain Tension: Ensure the chain is properly tensioned. A loose chain can cause the chainsaw to vibrate excessively and make cutting difficult. A chain tension that is too tight can cause excessive wear on the bar and chain. I usually check the chain tension before each use and adjust it as needed. The chain should be snug against the bar but still able to be pulled around by hand.
Chain Sharpness: A dull chain requires more force to cut, which can strain the engine and cause it to stall. Sharpen the chain regularly using a chainsaw file or a chain grinder. I prefer using a chainsaw file for quick touch-ups in the field and a chain grinder for more thorough sharpening.
Bar Lubrication: Ensure the bar and chain are properly lubricated. Insufficient lubrication can cause excessive wear on the bar and chain, and can also cause the engine to overheat. I always check the bar oil level before each use and refill it as needed.
Storage: When storing your chainsaw for an extended period, drain the fuel tank and run the engine until it stalls to remove any remaining fuel from the carburetor. This will prevent fuel from gumming up the carburetor and causing starting problems later on. I also remove the spark plug and pour a small amount of oil into the cylinder to lubricate the piston.

Strategic Insights for Efficient Wood Processing

Beyond simply fixing the chainsaw, let’s delve into some strategic insights for more efficient wood processing and firewood preparation.

Diagnose the Problem: Start by systematically troubleshooting your chainsaw using the steps outlined in this guide.
Gather Your Tools: Assemble the necessary tools and supplies for the repair, including screwdrivers, wrenches, carburetor cleaner, spark plug wrench, and replacement parts.
Follow the Instructions: Carefully follow the step-by-step instructions for each fix, paying attention to safety precautions.
Test and Adjust: After completing the repair, test the chainsaw to ensure it is running smoothly. Make any necessary adjustments to the carburetor or other components.
Preventative Maintenance: Implement a regular maintenance schedule to prevent future problems. Clean the air filter, fuel filter, and spark arrestor regularly, and replace the spark plug and fuel filter annually.
Continuous Learning: Continue to learn about chainsaw maintenance and wood processing techniques by reading books, watching videos, and attending workshops.

By following these steps, you can keep your Poulan chainsaw running smoothly and efficiently for years to come, allowing you to enjoy the satisfaction of cutting wood and preparing firewood with confidence. Remember, a well-maintained chainsaw is not only a valuable tool, but also a key to safe and efficient wood processing.