Poulan 2800 Chainsaw Repair Manual
The Poulan 2800 is a gas-powered chainsaw featuring a 2.8 cubic inch engine, automatic oiling system, chain brake, and anti-vibration handles. This manual provides essential information for safe operation, routine maintenance, troubleshooting, and repair procedures to keep your chainsaw in optimal working condition. Below are key sections covering safety, specifications, maintenance, troubleshooting, and repair instructions.
Safety Precautions
Always wear appropriate personal protective equipment (PPE) including safety glasses, hearing protection, gloves, chainsaw chaps, and steel-toed boots when operating or repairing the chainsaw.
| Hazard | Prevention |
|---|
| Kickback | Hold saw firmly with both hands; do not cut with tip of bar |
| Fuel Handling | Refuel in well-ventilated area away from ignition sources |
| Hot Surfaces | Allow engine to cool before performing maintenance |
| Sharp Chain | Always engage chain brake when not cutting |
| Electrical Shock | Disconnect spark plug wire before servicing |
Specifications
- Engine Displacement: 2.8 cu in (45cc)
- Power Output: 2.5 HP
- Fuel Capacity: 14.9 fl oz (440 ml)
- Oil Capacity: 8.5 fl oz (250 ml)
- Bar Length: 16" or 18" (standard)
- Chain Pitch: 3/8" low profile
- Chain Gauge: 0.050"
- Weight: 10.8 lbs (without bar & chain)
- Spark Plug: Champion RCJ-6Y or equivalent
Parts Identification
Key components: Front hand guard, Chain brake, Throttle trigger, Throttle lockout, Choke control, Primer bulb, Decompression valve (if equipped), Fuel cap, Oil cap, Muffler, Spark plug, Air filter cover, Starter grip, Rear handle, Chain tensioner.
Routine Maintenance
- Daily: Check chain tension, sharpness, and lubrication. Clean air filter. Inspect for loose fasteners.
- Weekly: Clean cooling fins. Check spark plug condition. Clean fuel filter.
- Monthly: Clean carburetor air passage. Check fuel lines for cracks. Inspect bar for wear.
- Seasonally: Replace spark plug. Clean muffler screen. Check anti-vibration mounts.
WARNING! Always disconnect spark plug before performing any maintenance.
Fuel & Oil System
Fuel Mix: Use 40:1 ratio of unleaded gasoline (minimum 89 octane) to 2-cycle engine oil. Do not use automotive oil or diesel fuel.
Oil System: Automatic chain oiler with manual override. Adjust oil flow rate via screw near oil pump.
- Fill oil reservoir with bar & chain oil only.
- Check oiler output by running saw at high RPM over cardboard.
- Clean oil passages if flow is restricted.
Chain & Bar Maintenance
- Chain Tension: Adjust when chain sags from bar. Loosen bar nuts, adjust tension screw, retighten nuts.
- Sharpening: Use round file matching chain pitch. Maintain 30° cutting angle. File all cutters evenly.
- Bar Maintenance: Clean bar groove weekly. Flip bar monthly for even wear. Dress bar rails with flat file.
- Lubrication: Ensure oil port on bar is clear. Lubricate sprocket nose bearing regularly.
Engine Troubleshooting
| Symptom | Possible Cause | Corrective Action |
|---|
| Engine won't start | No spark, flooded, fuel issue | Check spark plug; use correct starting procedure; verify fuel mix |
| Engine runs poorly | Dirty air filter, clogged fuel filter | Clean/replace air filter; replace fuel filter |
| Engine lacks power | Clogged muffler, carburetor adjustment | Clean muffler screen; adjust H & L needles |
| Engine overheats | Lean fuel mix, dirty cooling fins | Adjust carburetor richer; clean cooling fins |
| Excessive vibration | Loose components, worn mounts | Tighten all fasteners; replace anti-vibration mounts |
Carburetor Adjustment
Three adjustment screws: L (low speed), H (high speed), T (idle).
- Start engine and warm up for 5 minutes.
- Turn L screw clockwise until engine runs smoothly at low speed.
- Turn H screw for maximum RPM without exceeding recommended limit.
- Adjust T screw for stable idle (chain should not move).
- Final adjustment: Accelerate from idle to full throttle. Engine should respond quickly without hesitation.
CAUTION! Improper adjustment can cause engine damage. Use tachometer for precise settings.
Ignition System
Components: Flywheel, ignition coil, spark plug, stop switch.
- Spark Test: Remove spark plug, reconnect wire, ground plug to cylinder, pull starter. Look for bright blue spark.
- Coil Gap: Set air gap between coil legs and flywheel magnets to 0.010" (0.25mm).
- Testing: Check coil primary resistance (1-2 ohms) and secondary resistance (8-15k ohms).
- Replacement: Disconnect wires, remove mounting screws, install new coil with proper gap.
Disassembly & Assembly
Major component removal sequence:
- Remove bar and chain, fuel and oil.
- Remove starter assembly, air filter cover, carburetor.
- Remove cylinder cover, muffler, spark plug.
- Remove cylinder bolts, lift cylinder carefully.
- Remove piston pin clips, push out pin, remove piston.
- Remove crankshaft seals and bearings if replacing.
- Reassembly in reverse order using new gaskets.
Tip: Take photos during disassembly for reference. Use proper torque values for all fasteners.
Storage Guidelines
- Drain fuel tank and run engine until it stops.
- Remove spark plug, add 1 teaspoon of oil to cylinder, pull starter slowly to distribute.
- Clean entire saw thoroughly, especially cooling fins.
- Remove chain, clean and soak in oil. Store bar flat.
- Store in dry, cool place away from children.
Long-term Storage: Use fuel stabilizer if fuel cannot be drained completely.
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