Poulan 2150 Chainsaw Service Manual

The Poulan 2150 is a gas-powered chainsaw featuring a 2.1 cubic inch (34cc) engine, 16-inch guide bar, automatic oiler, anti-vibration system, and tool-free chain tensioning. This service manual provides comprehensive instructions for maintenance, troubleshooting, repair, and safety procedures to ensure optimal performance and longevity of your chainsaw. Below are key sections covering safety, specifications, operation, maintenance, and repair.

1. Safety Information 2. Specifications 3. Components & Controls 4. Assembly & First-Time Setup 5. Operation Instructions 6. Maintenance Schedule 7. Chain & Bar Maintenance 8. Engine Maintenance 9. Carburetor Adjustment 10. Troubleshooting 11. Parts List & Exploded Views

Safety Information

Always wear appropriate personal protective equipment (PPE): safety glasses, hearing protection, gloves, chainsaw chaps, and steel-toed boots. Operate in well-ventilated areas, keep bystanders away, and never operate on a ladder or unstable surface.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; use reduced-kickback chain; avoid tip contact.
Fuel Handling	Use fresh fuel mix (50:1); refuel only when engine is cool and off.
Chain Brake	Test before each use; engage during carry or if kickback occurs.
Hot Surfaces	Avoid contact with muffler and cylinder during/after operation.
Electrical Hazards	Keep away from power lines; do not operate in wet conditions.

Specifications

Engine: 2.1 cu in (34cc) 2-cycle gasoline engine.
Fuel/Oil Mix: 50:1 (Unleaded gasoline to 2-cycle oil).
Guide Bar Length: 16 inches (standard).
Chain Pitch: 0.325 inches.
Chain Gauge: 0.050 inches.
Oil Capacity: Approximately 6.8 fl oz (200ml).
Fuel Capacity: Approximately 12.2 fl oz (360ml).
Weight: 10.8 lbs (4.9 kg) without bar and chain.
Ignition: Electronic ignition with stop switch.
Vibration Damping: Anti-vibration system included.

Components & Controls

Key components: Front Hand Guard/Chain Brake, Throttle Trigger, Throttle Trigger Lockout, Stop Switch, Choke Control, Primer Bulb, Fuel Tank Cap, Oil Tank Cap, Rear Handle, Muffler, Spark Plug, Chain Tensioning Screw, Guide Bar, Saw Chain.

Controls: Throttle trigger (with lockout for safety), Choke lever (for cold starts), Primer bulb (to draw fuel into carburetor), Stop switch (to shut off engine), Chain brake lever (manual engagement).

Assembly & First-Time Setup

Unpack and inspect all parts. Assembly requires attaching guide bar and chain, filling fluids, and performing pre-operation checks.

Attach guide bar and chain: Loosen bar nuts, position chain with cutters facing forward on top of bar, fit bar over studs, adjust tension.
Fill oil tank: Use bar and chain oil; check for leaks.
Prepare fuel mix: 50:1 ratio of unleaded gasoline (89 octane min) and 2-cycle engine oil. Shake well.
Fill fuel tank: Use funnel to avoid spills.
Pre-operation check: Verify chain tension, chain brake function, throttle operation, and all fasteners are tight.

WARNING! Never use automotive motor oil or dirty gasoline. Ensure chain is properly tensioned before starting.

Operation Instructions

Starting procedure (cold engine):

Place saw on flat, clear ground. Engage chain brake.
Move choke lever to FULL CHOKE position. Press primer bulb 5-6 times.
Pull starter rope briskly until engine "pops" (usually 1-3 pulls).
Move choke lever to HALF CHOKE position. Pull starter rope until engine starts.
Allow engine to warm up for 30 seconds, then squeeze throttle to disengage choke.
Disengage chain brake before cutting.

Cutting Techniques: Use lower quadrant of bar for cutting; let saw do the work; avoid pinching bar. Always shut off engine when not in use or during transport.

Maintenance Schedule

Interval	Task
Before each use	Check chain tension, sharpness, and lubrication; inspect for loose fasteners; test chain brake.
Every 5 hours	Clean air filter; check spark plug condition.
Every 10 hours	Clean cooling fins; inspect fuel filter; clean guide bar groove.
Every 20 hours	Replace spark plug; clean muffler screen (if equipped).
Seasonally	Drain fuel for storage; inspect and replace worn bar and chain.

Chain & Bar Maintenance

Proper chain tension: Chain should be snug against bar but pull freely by hand. Adjust via side tensioning screw with bar nuts loosened.

Sharpening: Use round file matching chain pitch (0.325"). Maintain 30° filing angle; file all cutters evenly.
Bar maintenance: Clean bar groove weekly; flip bar monthly for even wear; check for burrs and file smooth.
Lubrication: Ensure oiler port is clear; always run with bar and chain oil; adjust oil flow if adjustable.

CAUTION! Always wear heavy gloves when handling chain. Disconnect spark plug wire during maintenance.

Engine Maintenance

Air Filter: Clean with soapy water, dry thoroughly, lightly oil with 2-cycle oil before reinstalling. Replace if torn.

Spark Plug: Standard NGK BPMR7A or equivalent. Gap: 0.025 inches (0.63mm). Clean electrode with wire brush; replace if worn or fouled.

Fuel System: Replace in-tank fuel filter annually. Clean fuel cap vent. Use fuel stabilizer for storage over 30 days.

Cooling System: Keep cylinder fins clean of debris to prevent overheating.

Carburetor Adjustment

Factory settings typically suffice. Adjustment may be needed for altitude or temperature changes. Locate H (high speed), L (low speed), and T (idle) screws.

Warm up engine fully.
Set idle speed (T screw): Adjust so chain does not move at idle but engine runs smoothly.
Adjust L screw: Turn clockwise until engine speed drops, then counterclockwise 1/4 turn for best acceleration.
Adjust H screw: CAUTION: Excessive RPM can damage engine. For professional adjustment only; refer to emissions regulations.

WARNING! Improper adjustment can cause engine damage or unsafe operation. Consult a qualified technician if unsure.

Troubleshooting

Problem	Possible Cause	Solution
Engine won't start	No spark, flooded, stale fuel, clogged filter	Check spark plug; wait if flooded; use fresh fuel mix; clean air filter.
Engine starts then dies	Clogged fuel filter, carburetor issue, vent problem	Replace fuel filter; clean carburetor; check fuel cap vent.
Poor cutting performance	Dull chain, improper tension, low chain oil	Sharpen chain; adjust tension; fill oil tank; check oiler.
Excessive vibration	Loose parts, unbalanced chain, damaged bar	Tighten all fasteners; sharpen chain evenly; inspect/replace bar.
Chain won't stop moving at idle	Idle speed too high	Adjust idle screw (T) counterclockwise.
Chain oil not flowing	Empty oil tank, clogged oil port, faulty oiler	Fill tank; clean bar oil holes; check oil pump.

Parts List & Exploded Views

Refer to official Poulan parts diagrams for part numbers. Common replacement parts include:

Spark Plug: NGK BPMR7A or equivalent.
Air Filter: Poulan 530069854.
Fuel Filter: Poulan 530035322.
Drive Sprocket: Rim sprocket type, part number varies.
Guide Bar: 16" .325 pitch, .050 gauge.
Saw Chain: 16" .325 pitch, .050 gauge, 56 drive links (standard).

Service: For technical support or genuine parts, contact Poulan customer service at 1-800-554-6723 or visit www.poulanpro.com.