Poulan 260 Pro Chainsaw Repair Manual

The Poulan 260 Pro is a professional-grade chainsaw featuring a 42cc 2-cycle engine, 16-inch guide bar, automatic oiler, chain brake, and anti-vibration system. This manual provides comprehensive repair, maintenance, and troubleshooting information for owners and technicians. Below are key sections covering safety, specifications, disassembly, engine repair, fuel system, ignition, lubrication, bar/chain maintenance, troubleshooting, and parts diagrams.

1. Safety Precautions 2. Specifications 3. Tools Required 4. Disassembly Procedure 5. Engine Repair 6. Fuel System 7. Ignition System 8. Lubrication System 9. Bar & Chain Maintenance 10. Troubleshooting 11. Parts Diagrams

Safety Precautions

Always wear appropriate PPE: safety glasses, gloves, hearing protection, and chainsaw chaps. Work in a well-ventilated area. Disconnect spark plug before servicing. Use only genuine Poulan parts.

Hazard	Prevention
Fuel Fire/Explosion	Drain fuel before repair; no sparks or flames nearby
Chain Kickback	Engage chain brake when not cutting; maintain proper chain tension
Carbon Monoxide	Operate outdoors only; never in enclosed spaces
Sharp Edges	Wear cut-resistant gloves when handling chain or bar
Hot Surfaces	Allow engine to cool before touching muffler or cylinder

Specifications

Model: Poulan 260 Pro
Engine: 42cc, 2-cycle, air-cooled
Fuel: 50:1 gas/oil mix (89 octane minimum)
Bar Length: 16 inches (40 cm)
Chain Pitch: 3/8" low-profile
Chain Gauge: 0.050"
Oil Capacity: 8.5 fl oz (250 ml)
Fuel Capacity: 14.9 fl oz (440 ml)
Ignition: Electronic, 12,000 RPM max
Weight: 10.8 lbs (4.9 kg) without bar & chain

Tools Required

Standard toolkit for repair: socket set (8mm-13mm), Torx T27, spark plug wrench, flat/Phillips screwdrivers, needle-nose pliers, compression tester, feeler gauge, carburetor adjustment tool.

Remove bar/chain: Loosen nuts with 13mm socket.
Access carburetor: Remove air filter cover (Phillips screwdriver).
Check spark: Use spark plug wrench to remove plug.

WARNING! Use correct tools to avoid stripping fasteners.

Disassembly Procedure

Step-by-step teardown for major repairs.

Drain fuel and bar oil into approved containers.
Remove bar, chain, and clutch cover (13mm socket).
Disconnect spark plug wire and remove starter assembly (3x 8mm bolts).
Remove muffler (2x 10mm bolts) and carburetor box.
Separate engine from chassis (4x 12mm bolts).

CAUTION! Label parts and fasteners for reassembly.

Engine Repair

Cylinder, piston, crankshaft, and seals service.

Component	Inspection	Specification
Compression	Use compression tester	Min 110 PSI at wide-open throttle
Piston Rings	Check for scoring or wear	Replace if gap exceeds 0.020"
Crank Seals	Inspect for leaks	No air leakage when pressurized
Spark Plug	Check electrode gap	0.025" (0.63 mm)

Note: Replace entire piston/cylinder if scoring is deep.

Fuel System

Carburetor (Walbro WT- series) repair and adjustment.

Remove carburetor: Disconnect fuel line and throttle linkage.
Clean: Soak in carb cleaner; replace diaphragm and gaskets.
Adjust: Initial settings - L: 1-1/4 turns out, H: 1 turn out.
Test: Fine-tune at operating temperature for smooth acceleration.

Tip: Always use fresh fuel mix to prevent varnish buildup.

Ignition System

Testing coil, spark plug, and kill switch.

Spark Test: Remove plug, ground to cylinder, pull starter - look for bright blue spark.
Coil Gap: Set at 0.010" (0.25 mm) between coil legs and flywheel.
Kill Switch: Test continuity; replace if circuit is always closed.
Flywheel: Check for cracks; torque nut to 35 ft-lbs (47 Nm).

Lubrication System

Automatic oiler maintenance and troubleshooting.

Check oil pump: Remove clutch drum; inspect pump gear for wear.
Clear passages: Use compressed air on oil output hole.
Adjust flow: Turn screw clockwise to increase oil output.
Test: Run saw at high RPM over cardboard - should see oil splatter.

WARNING! Never run saw without bar oil to avoid bar/chain damage.

Bar & Chain Maintenance

Sharpening, tensioning, and replacement.

Task	Procedure	Frequency
Sharpening	Use round file (5/32"); maintain 30° angle	Every 2-3 hours of use
Tensioning	Adjust until chain snaps back when pulled	Before each use
Bar Flipping	Flip bar monthly to ensure even wear	Monthly
Groove Cleaning	Clean bar groove with narrow screwdriver	When replacing chain

Troubleshooting

Symptom	Possible Cause	Corrective Action
Won't start	No spark, flooded, fuel issue	Check spark plug; dry cylinder; clean carburetor
Runs then dies	Clogged fuel filter, vent	Replace fuel filter; clear tank vent
Poor cutting power	Dull chain, low compression	Sharpen chain; check compression
Chain won't oil	Clogged oiler, pump failure	Clean oil passages; replace pump
Excessive vibration	Loose fasteners, bent crankshaft	Tighten all bolts; inspect crankshaft

Reset: After repair, retune carburetor for optimal performance.

Parts Diagrams

Reference diagrams for ordering replacement parts.

Engine Assembly: Cylinder, piston, crankshaft, seals (Part #530069853)
Carburetor Kit: Includes diaphragm, gaskets, needles (Part #530035120)
Ignition Coil: Electronic module (Part #530069857)
Chain Brake Assembly: Band, handle, spring (Part #530069860)
Bar & Chain Set: 16-inch Oregon replacement (Part #160VXL)

Ordering: Contact Poulan dealer or visit www.poulanpro.com with model number.