Poulan Pro PR5020 Recoil Spring (Step-by-Step)
To replace the recoil spring on a Poulan Pro PR5020, first confirm the correct part for your saw’s starter cover and revision. Disconnect the spark-plug boot, contain the spring, and record how the pulley and spring hooks sit. Fit the spring in its original orientation, then test smooth rope return and pawl engagement before reconnecting the plug.
If the starter handle hangs loose or the rope will not retract, a broken or disengaged recoil spring may be the cause. The starter cover also holds parts that can release suddenly, so slow, controlled work matters. The steps below help you check the fault, choose a safe repair route, and verify the result without replacing parts by guesswork.
Confirm the fault and the correct part
The recoil spring turns the starter pulley back after you pull the rope. A failed spring can leave the handle hanging or stop the pulley from returning. First separate a spring fault from a rope, pulley, or pawl problem, then identify a replacement that fits your PR5020.
Check the starter before ordering
A recoil starter includes the rope, handle, pulley, spring, and starter pawls. The pawls engage the engine during a pull. If the rope pulls out but does not turn the engine, the pawls or their engagement may be at fault; that symptom alone does not prove the spring is broken.
Look for these clues:
- Handle stays out: The spring may be broken, unhooked, or unable to return the pulley.
- Rope is frayed or jammed: The rope, handle knot, guide, or pulley groove may be the problem.
- Pulley turns but does not engage: Inspect the pawls and related starter parts.
- Starter cover is cracked or distorted: A spring-only repair may not be safe or reliable.
Do not change carburetor settings to fix a rope that will not retract or a starter that will not engage. Those are separate systems.
Verify PR5020 compatibility
The PR5020 is a 50 cc chainsaw, but displacement alone does not confirm that a spring or starter assembly will fit. Check the saw’s product identification and serial or revision details against the parts listing or applicable manufacturer documentation. Compare the replacement with the removed part: hook shape, spring diameter, and hook locations should match.
| Part or detail | What to verify | Why it matters |
|---|---|---|
| Recoil spring or assembly | PR5020 fit and the saw’s revision | Similar-looking parts may differ |
| Spring hooks | Shape and end locations | Both ends must engage as designed |
| Pulley and cover | Configuration and condition | A mismatched or damaged part can bind |
| Rope | Length, condition, and routing | Incorrect routing can stop return |
If the spring is loose, distorted, corroded, or difficult to contain, use a compatible complete recoil assembly rather than trying to wind an exposed spring by hand. When fit is unclear, stop and check the parts information before opening the starter.
Prepare the saw and work area
Safe preparation keeps the engine from starting and reduces the chance of a spring escaping during repair. Park the saw on a stable bench, switch it off, let the engine cool, and disconnect the spark-plug boot. Wear eye protection and gloves; keep your face and hands clear of the spring’s path.
Before taking anything apart, photograph the starter cover and pulley. Note the rope route, pulley orientation, and where each spring hook sits. A photo gives you a reference if the parts move during removal.
Gather the correct replacement, suitable hand tools, and a spring cassette or complete recoil assembly if available. Keep small fasteners together. Do not flood the starter mechanism with solvent or lubricant; sawdust and oil residue can be removed with a brush and dry cloth.
Replace the recoil spring step by step
Work in stages and keep the spring contained. A recoil spring stores energy and can release abruptly. If it begins to escape or will not sit correctly, stop rather than trying to hold or force it into place.
1. Remove the starter cover
Confirm that the spark-plug boot is disconnected and secured away from the plug. Remove the starter-cover fasteners and lift the cover straight off. Keep control of the rope handle and pulley so the rope cannot snap back.
If the pulley remains under tension, do not let it spin freely. Ease the tension off gradually while keeping the spring contained. The exact removal method can vary by starter design, so use the parts layout for your saw rather than forcing a component.
2. Remove the pulley and contain the spring
Remove the pulley only as needed to reach the spring. Keep the spring inside its cassette or housing whenever possible. A cassette helps contain the coil; an exposed spring is much harder and riskier to handle.
Do not pry a loose, tensioned spring toward your face. Do not try to wind an exposed spring by hand without proper containment and eye protection. If the cassette is cracked, the spring is badly distorted, or you cannot control the spring safely, replace the complete recoil assembly or have a qualified repair shop handle it.
3. Seat the replacement spring
Place the replacement spring in the same orientation as the original. Seat its outer end in the starter housing and its inner end in the pulley, using the designed hook points. Wind or load the spring into its cassette or pocket as that starter assembly requires.
Check that the spring lies flat. It must not cross over itself, buckle, or sit proud of its pocket. Both hooks must be fully engaged. If the spring will not seat cleanly, stop and recheck the part number, orientation, and fit. Forcing it can damage the spring, pulley, or housing.
4. Reassemble and set rope return
Reinstall the pulley and route the rope through the cover and handle as it was before removal. Make sure the rope sits in the pulley groove and does not rub, bind, or protrude where the pulley turns. Inspect the handle knot, rope guide, pawls, and cover mounting points while they are accessible.
Preload the pulley only enough for it to retract the handle fully. The correct amount depends on the starter design; do not add turns by guesswork. Refit the cover, aligning the parts without force. Tighten the cover screws evenly and securely. Do not use an unverified torque value or overtighten screws into the plastic housing.
Test the repair before starting
Testing with the spark plug still disconnected lets you check the starter without starting the engine. Pull the handle slowly several times. The rope should extend smoothly, the pulley should turn without binding, and the handle should return fully each time.
The starter pawls should engage during a pull. If the rope sticks, the handle remains out, or the pulley rubs, stop and inspect the spring seating, rope route, pulley, and cover alignment. Do not reconnect the spark-plug boot until the assembly passes these checks.
| Test result | Likely area to inspect | Next step |
|---|---|---|
| Rope extends and returns smoothly | Spring and rope return | Continue checks |
| Handle does not return fully | Spring seating, preload, or rope friction | Reopen and inspect |
| Rope binds or scrapes | Rope route, guide, pulley groove, or cover fit | Correct the obstruction |
| Rope pulls without pawl engagement | Pawls or starter engagement parts | Inspect or replace worn parts |
| Cover will not seat without force | Misalignment or damaged parts | Remove and realign; do not force |
Only after the starter passes should you reconnect the plug boot. If the saw still will not start, the recoil repair may be complete while a separate ignition, fuel, or compression fault remains. Diagnose that problem on its own; do not alter the carburetor to compensate for a starter fault.
Repair examples and when to replace the assembly
These examples show how symptoms can guide inspection; they are diagnostic scenarios, not proof that every PR5020 has the same failure. A spring-only repair makes sense only when the spring and surrounding parts can be handled safely and fit is confirmed.
Loose handle, intact rope
A handle that stays out, with an intact rope and guide, points toward a spring that has broken or come unhooked. After disconnecting the plug boot, inspect the pulley and spring. If the spring remains safely contained and the housing is sound, a compatible spring repair may be suitable.
Frayed rope and cracked pulley
A frayed rope can snag in the pulley, while a cracked pulley may fail to guide the rope or hold the spring correctly. Replacing only the spring would leave damaged parts in service. Replace the affected parts or the complete compatible recoil assembly, then repeat the slow-pull test.
Spring will not sit flat
If the spring crosses, buckles, or will not engage both hooks, do not force the pulley or cover into place. Check that the replacement matches the saw and is oriented correctly. If you cannot contain and seat it safely, use a complete recoil assembly or seek repair help.
FAQ
How do I know the PR5020 recoil spring is broken?
A handle that stays extended or a pulley that will not return can indicate a broken or disengaged spring. Check the rope, guide, pulley, and spring before ordering parts.
Will any Poulan recoil spring fit the PR5020?
No. Confirm fit for the PR5020 and the saw’s serial or revision details. Compare the spring’s hooks, diameter, and end locations with the original.
Can I replace just the spring?
Yes, if the correct spring fits and you can keep it safely contained while installing it. Replace the complete recoil assembly if the spring is distorted or the cassette, pulley, or housing is damaged.
Do I need to remove the spark plug?
The key safety step is disconnecting the spark-plug boot and securing it away from the plug before opening the starter. Keep it disconnected during the slow-pull test.
Which way should the spring be wound?
Use the orientation shown by the original spring and the starter design. Record hook positions before removal; do not guess or force a spring that will not seat.
How much preload should I add?
Only enough for the pulley to retract the handle fully. There is no verified universal turn count for every starter configuration; test smooth return and avoid adding turns by guesswork.
Should I lubricate the recoil spring?
Do not flood the starter with solvent or lubricant. Clear sawdust and residue with a brush and dry cloth, and follow applicable manufacturer service guidance for lubrication.
Can I start the saw if the rope does not retract fully?
Do not rely on a starter that binds or fails to return. Correct the spring, rope, pulley, or cover problem and confirm smooth operation before reconnecting the plug boot.
Do carburetor adjustments fix a starter that will not engage?
No. The recoil mechanism and carburetor are separate systems. Inspect the rope, pulley, and pawls for a starter engagement fault.
What should I do if the spring escapes its housing?
Do not grab or wind a tensioned spring by hand. Keep your face clear, use proper containment and eye protection, or replace the complete recoil assembly or seek qualified service.
The repair is complete only when the cover fits without force, the rope extends and returns smoothly, and the pawls engage on a pull. Store the saw switched off with the starter handle returned, and keep the starter area clear of sawdust and oil residue.
(This article was written by one of our staff writers, Robert Callahan. Visit our Meet the Team page.)
