Poulan Pro 20 Inch Bar And Chain Guide (5 Expert Tips)

Alright, let’s dive into the world of chainsaws, specifically focusing on maximizing the performance and lifespan of your Poulan Pro 20-inch bar and chain. I’ve spent years in the woods, from felling trees for sustainable lumber to prepping firewood for the long winters. I’ve seen firsthand how a well-maintained chainsaw can be a reliable workhorse, and how neglecting it can lead to frustration and even dangerous situations. The Poulan Pro, while a common and accessible model, demands respect and understanding to get the most out of it. These aren’t just tips I pulled from a manual; they are lessons etched in sweat, sawdust, and the occasional close call. So, let’s get started.

Poulan Pro 20 Inch Bar and Chain Guide: 5 Expert Tips for Peak Performance

Understanding the Importance of a Well-Maintained Bar and Chain

Before we get into the specifics, let’s understand why a healthy bar and chain are crucial. A dull chain not only makes cutting harder and slower, but it also puts extra strain on the chainsaw engine, leading to premature wear. A damaged or improperly lubricated bar can cause the chain to bind, kickback, or even break, posing a significant safety hazard. In my experience, a well-maintained chainsaw is a safer chainsaw, a more efficient chainsaw, and ultimately, a more cost-effective chainsaw.

Think of it like this: I once had a crew felling some mature oaks for a barn restoration project. We had two identical Poulan Pro chainsaws, but one was meticulously maintained, and the other, well, let’s just say it was treated more like a rental tool. The difference in performance was astounding. The well-maintained saw sliced through those oaks with ease, while the neglected one struggled, overheated, and constantly needed adjustments. The lesson? A little maintenance goes a long way.

Tip 1: Chain Sharpening – The Foundation of Efficient Cutting

Chain sharpening is the single most important aspect of chainsaw maintenance. A sharp chain bites into the wood cleanly, reducing the effort required and minimizing the risk of kickback.

Why Sharpen Regularly? A dull chain produces sawdust instead of chips, requires more force to cut, and increases the risk of kickback. Kickback is a sudden, uncontrolled upward or backward movement of the chainsaw, and it can be extremely dangerous. I’ve seen kickback send a chainsaw flying, and I can tell you, it’s not a pleasant experience.
Tools for Sharpening: You have a few options:
- Round File and Filing Guide: This is the most common and affordable method. You’ll need a round file that matches the size of your chain’s cutters (typically 5/32″ or 3/16″ for a Poulan Pro 20-inch chain), a flat file for depth gauges, and a filing guide to maintain the correct angle. I recommend a Pferd or Oregon filing kit. I’ve tried cheaper brands, but they just don’t hold up.
- Electric Chain Sharpener: These sharpeners offer more precision and speed, especially if you have a lot of chains to maintain. Brands like Oregon and Timberline offer reliable electric sharpeners. I use an electric sharpener in my shop for sharpening multiple chains quickly.
- Handheld Power Sharpener: These are portable and convenient for sharpening in the field. They use a small grinding stone to sharpen the cutters.
Step-by-Step Sharpening with a Round File:
1. Secure the Chainsaw: Place the chainsaw in a vise or on a stable surface. Engage the chain brake.
2. Identify the Cutters: Examine the chain and identify the left and right-hand cutters. You’ll need to sharpen each side alternately.
3. Position the File: Place the round file in the cutter, using the filing guide to maintain the correct angle (typically 30 degrees for the top plate and 10 degrees for the side plate). The filing guide will also help you maintain the correct depth.
4. File the Cutter: Using smooth, even strokes, file the cutter from the inside out. Apply light pressure and maintain a consistent angle. Count the number of strokes for each cutter and repeat the same number of strokes for all cutters on that side. I usually aim for 3-5 strokes per cutter.
5. Repeat for All Cutters: Rotate the chain and repeat the process for all cutters on that side. Then, switch to the other side and repeat.
6. Lower the Depth Gauges (Rakers): After sharpening, you’ll need to lower the depth gauges (also known as rakers). These are the small projections in front of each cutter. Use a flat file and a depth gauge tool to lower the rakers to the recommended height (typically 0.025″ for a Poulan Pro chain). This ensures that the cutters can bite into the wood properly. I use a piece of cardboard as a guide for my flat file to ensure that i’m filing evenly.
7. Check Your Work: After sharpening, inspect the chain to ensure that all cutters are sharp and the depth gauges are properly set. Run your finger (carefully!) along the cutters. They should feel sharp and aggressive.
Personal Experience and Insights: I used to be hesitant about sharpening my own chains, thinking it was too complicated. I relied on taking them to a professional. However, after a few frustrating experiences with poorly sharpened chains, I decided to learn myself. It took some practice, but now I can sharpen a chain in about 15 minutes, and I have much more control over the quality of the sharpening.
Case Study: I was helping a friend clear some brush on his property. He had been struggling with a dull chain for hours, making slow progress and exhausting himself. I sharpened his chain using the round file method, and the difference was immediate. He was able to cut through the brush much faster and with less effort. He was amazed at how much of a difference a sharp chain could make.

Tip 2: Bar Maintenance – Ensuring Smooth Chain Operation

The bar is the backbone of your chainsaw, guiding the chain and supporting the cutting process. Proper bar maintenance is essential for smooth chain operation and preventing premature wear.

Why Bar Maintenance Matters: A damaged or worn bar can cause the chain to bind, overheat, and even break. It can also lead to uneven cutting and increased risk of kickback. I’ve seen bars that were so worn they looked like they had been through a war, and they were causing all sorts of problems.
Key Bar Maintenance Tasks:
- Cleaning the Bar Groove: The bar groove is the channel that guides the chain. It can become clogged with sawdust, dirt, and oil, which can restrict chain movement and cause overheating. Use a bar groove cleaner or a small screwdriver to clean the groove regularly. I clean mine after every use.
- Filing the Bar Rails: The bar rails are the edges of the bar that support the chain. Over time, they can become worn or burred, which can cause the chain to bind. Use a flat file to smooth the bar rails and remove any burrs. I check mine every other time I sharpen my chain.
- Checking Bar Straightness: A bent bar can cause the chain to run unevenly and increase the risk of kickback. Use a straightedge to check the bar for straightness. If the bar is bent, it may need to be replaced.
- Lubricating the Bar Tip Sprocket: Some bars have a sprocket at the tip that helps to reduce friction and improve chain speed. Make sure to lubricate the sprocket regularly with grease using a grease gun. I grease mine every time I fill up with gas.
Step-by-Step Bar Maintenance:
1. Remove the Chain: Remove the chain from the bar.
2. Clean the Bar Groove: Use a bar groove cleaner or a small screwdriver to clean the bar groove. Remove all sawdust, dirt, and oil.
3. File the Bar Rails: Use a flat file to smooth the bar rails and remove any burrs. File in one direction only, and maintain a consistent angle.
4. Check Bar Straightness: Use a straightedge to check the bar for straightness. Place the straightedge along the bar and look for any gaps.
5. Lubricate the Bar Tip Sprocket: If your bar has a tip sprocket, use a grease gun to lubricate it with grease.
6. Reinstall the Chain: Reinstall the chain on the bar, ensuring that it is properly seated in the groove.
Personal Experience and Insights: I once neglected to clean the bar groove on my chainsaw, and it caused the chain to overheat and bind. The bar turned blue from the heat, and I had to replace it. It was a costly mistake that taught me the importance of regular bar maintenance.
Case Study: I was working with a logger who had a chainsaw with a severely worn bar. The bar rails were so worn that the chain was constantly binding. He was struggling to make clean cuts, and the chainsaw was vibrating excessively. I recommended that he replace the bar, and he was amazed at how much of a difference it made. The chainsaw ran much smoother, and he was able to make clean cuts with ease.

Tip 3: Proper Chain Lubrication – Extending Chain and Bar Life

Chain lubrication is critical for reducing friction, preventing overheating, and extending the life of your chain and bar. Without proper lubrication, the chain and bar will wear out quickly, and the chainsaw will be more likely to experience problems.

Why Chain Lubrication is Essential: The chain travels at high speed around the bar, generating a significant amount of friction. Lubrication reduces this friction, preventing the chain and bar from overheating and wearing out prematurely. I’ve seen chains seize up completely from lack of lubrication, and it’s not a pretty sight.
Choosing the Right Chain Oil: Use a high-quality chain oil specifically designed for chainsaws. Avoid using motor oil or other types of oil, as they may not provide adequate lubrication and can damage the chain and bar. I recommend using a chain oil that is formulated with tackifiers, which help the oil to cling to the chain and bar. I generally use a bar and chain oil from Stihl or Husqvarna.
Checking the Oil Level: Check the oil level in the oil reservoir before each use. Refill the reservoir as needed. It’s better to over-lubricate than to under-lubricate.
Adjusting the Oil Flow: Some chainsaws have an adjustable oil flow. Adjust the oil flow according to the type of wood you are cutting and the ambient temperature. When cutting hardwoods or in hot weather, you may need to increase the oil flow. I usually keep the oil flow set to the maximum.
Signs of Insufficient Lubrication: If the chain is smoking, overheating, or binding, it may not be getting enough lubrication. Check the oil level and adjust the oil flow as needed.
Step-by-Step Chain Lubrication:
1. Check the Oil Level: Check the oil level in the oil reservoir.
2. Refill the Reservoir: If the oil level is low, refill the reservoir with chain oil.
3. Adjust the Oil Flow: If your chainsaw has an adjustable oil flow, adjust it according to the type of wood you are cutting and the ambient temperature.
4. Monitor Lubrication: While cutting, monitor the chain to ensure that it is getting adequate lubrication. The chain should be coated with oil and should not be smoking or overheating.
Personal Experience and Insights: I once ran my chainsaw without checking the oil level, and the chain seized up and broke. It was a dangerous situation, and it taught me the importance of always checking the oil level before each use.
Case Study: I was working with a tree service company that was using a cheap chain oil. The chains were wearing out quickly, and the bars were becoming damaged. I recommended that they switch to a high-quality chain oil, and they saw a significant improvement in chain and bar life. They also noticed that the chainsaws were running cooler and smoother.

Tip 4: Chain Tension Adjustment – Preventing Chain Damage and Kickback

Proper chain tension is crucial for safe and efficient chainsaw operation. A chain that is too loose can come off the bar, while a chain that is too tight can bind and overheat. Both situations can be dangerous and can damage the chain and bar.

Why Chain Tension Matters: A properly tensioned chain will run smoothly and efficiently, reducing the risk of kickback and extending the life of the chain and bar. I’ve seen chains come off the bar at high speed, and it’s a scary experience.
Checking Chain Tension: Check the chain tension before each use and after every few cuts. The chain should be snug against the bar but should still be able to be pulled around the bar by hand.
Adjusting Chain Tension: Most chainsaws have a chain tension adjustment screw or knob. Use this to adjust the chain tension. Loosen the bar nuts, adjust the tension, and then tighten the bar nuts.
Chain Tension in Different Temperatures: The chain tension will change with temperature. When the chain is cold, it will be tighter than when it is hot. Adjust the chain tension accordingly.
Signs of Improper Chain Tension: If the chain is sagging or coming off the bar, it is too loose. If the chain is binding or overheating, it is too tight.
Step-by-Step Chain Tension Adjustment:
1. Loosen the Bar Nuts: Loosen the bar nuts that hold the bar in place.
2. Adjust the Chain Tension: Use the chain tension adjustment screw or knob to adjust the chain tension. Turn the screw clockwise to tighten the chain and counterclockwise to loosen the chain.
3. Check the Chain Tension: Check the chain tension by pulling the chain around the bar by hand. The chain should be snug against the bar but should still be able to be pulled around the bar by hand.
4. Tighten the Bar Nuts: Tighten the bar nuts to secure the bar in place.
Personal Experience and Insights: I once had a chain that was too loose, and it came off the bar while I was cutting a large log. The chain whipped around and hit me in the leg. I was lucky that I wasn’t seriously injured, but it was a painful reminder of the importance of proper chain tension.
Case Study: I was working with a homeowner who was having trouble with his chainsaw. The chain was constantly coming off the bar. I checked the chain tension and found that it was way too loose. I adjusted the chain tension and showed him how to check it properly. He was able to use his chainsaw without any further problems.

Tip 5: Storage and Maintenance – Protecting Your Investment

Proper storage and maintenance are essential for protecting your chainsaw investment and ensuring that it is ready to use when you need it. Neglecting these aspects can lead to corrosion, fuel degradation, and other problems that can shorten the life of your chainsaw.

Why Storage and Maintenance Matter: A properly stored and maintained chainsaw will last longer and perform better. I’ve seen chainsaws that were left outside in the rain and snow, and they were rusted and corroded beyond repair.
Cleaning the Chainsaw: After each use, clean the chainsaw to remove sawdust, dirt, and oil. Use a brush or compressed air to clean the engine, bar, and chain.
Draining the Fuel Tank: If you are not going to use the chainsaw for an extended period of time, drain the fuel tank. Gasoline can degrade over time and can damage the engine.
Storing the Chainsaw: Store the chainsaw in a dry, protected location. Avoid storing it in direct sunlight or in damp conditions.
Sharpening the Chain: Sharpen the chain before storing the chainsaw. A sharp chain will be ready to use when you need it.
Checking the Air Filter: Check the air filter regularly and clean or replace it as needed. A dirty air filter can restrict airflow to the engine and can cause it to overheat.
Replacing the Spark Plug: Replace the spark plug annually or as needed. A worn spark plug can cause the engine to run poorly.
Step-by-Step Storage and Maintenance:
1. Clean the Chainsaw: Clean the chainsaw to remove sawdust, dirt, and oil.
2. Drain the Fuel Tank: Drain the fuel tank.
3. Store the Chainsaw: Store the chainsaw in a dry, protected location.
4. Sharpen the Chain: Sharpen the chain.
5. Check the Air Filter: Check the air filter and clean or replace it as needed.
6. Replace the Spark Plug: Replace the spark plug annually or as needed.
Personal Experience and Insights: I once left my chainsaw outside in the rain, and it rusted and corroded. The engine was difficult to start, and the chain was binding. I had to spend a lot of time and money to repair it. It taught me the importance of proper storage and maintenance.
Case Study: I was working with a landscaping company that had a fleet of chainsaws. They were not properly storing or maintaining their chainsaws, and they were experiencing frequent breakdowns. I recommended that they implement a storage and maintenance program, and they saw a significant improvement in chainsaw reliability.

Safety First: Personal Protective Equipment (PPE)

No discussion about chainsaws is complete without emphasizing safety. Chainsaws are powerful tools, and they can be dangerous if not used properly. Always wear appropriate personal protective equipment (PPE) when operating a chainsaw.

Essential PPE:
- Helmet: Protects your head from falling debris.
- Eye Protection: Safety glasses or a face shield protect your eyes from sawdust and flying debris.
- Hearing Protection: Earplugs or earmuffs protect your hearing from the loud noise of the chainsaw.
- Gloves: Protect your hands from cuts and abrasions.
- Chainsaw Chaps: Protect your legs from chainsaw cuts. These are arguably the most important piece of PPE.
- Steel-Toed Boots: Protect your feet from falling logs and chainsaw cuts.
Why PPE is Crucial: PPE can significantly reduce the risk of injury when operating a chainsaw. I’ve seen PPE save people from serious injuries.
Personal Experience and Insights: I once witnessed a chainsaw kickback and cut a logger in the leg. He was wearing chainsaw chaps, which prevented a serious injury. The chaps absorbed the impact of the chain and prevented it from cutting through his leg.
Case Study: A study by the National Institute for Occupational Safety and Health (NIOSH) found that wearing chainsaw chaps reduces the risk of leg injuries by 45%.

Strategic Insights: Optimizing Your Cutting Techniques

Beyond maintenance, your cutting techniques play a significant role in the life of your bar and chain.

Felling Techniques: Proper felling techniques can prevent the bar from pinching and reduce the risk of kickback. Always plan your felling cut carefully and ensure that you have a clear escape route.
Limbing Techniques: Use proper limbing techniques to avoid cutting into the ground, which can dull the chain. Keep the bar and chain away from rocks and other debris.
Bucking Techniques: Use proper bucking techniques to avoid pinching the bar and chain. Support the log properly and make sure that the cut is not under tension.
Avoiding Obstacles: Be aware of your surroundings and avoid cutting into obstacles such as rocks, nails, and wire. These can damage the chain and bar.
Using Wedges: Use wedges to prevent the log from pinching the bar and chain. Wedges can also help to control the direction of the fall.
Strategic Advantages: Optimizing your cutting techniques can improve your efficiency, reduce the risk of injury, and extend the life of your bar and chain.

Next Steps: Putting These Tips into Practice

Now that you have a solid understanding of Poulan Pro 20-inch bar and chain maintenance, it’s time to put these tips into practice.

Inspect Your Chainsaw: Before each use, inspect your chainsaw to ensure that it is in good working condition. Check the chain tension, oil level, and air filter.
Sharpen Your Chain: Sharpen your chain regularly to maintain peak performance.
Maintain Your Bar: Clean and maintain your bar to ensure smooth chain operation.
Lubricate Your Chain: Use a high-quality chain oil to lubricate your chain.
Adjust Chain Tension: Adjust the chain tension properly to prevent chain damage and kickback.
Store Your Chainsaw: Store your chainsaw properly to protect your investment.
Wear PPE: Always wear appropriate personal protective equipment (PPE) when operating a chainsaw.
Practice Safe Cutting Techniques: Use proper cutting techniques to reduce the risk of injury and extend the life of your bar and chain.

By following these expert tips, you can maximize the performance and lifespan of your Poulan Pro 20-inch bar and chain and enjoy years of reliable service. Remember, a little maintenance goes a long way.

Poulan Pro 20 Inch Bar and Chain Guide (5 Expert Tips)