Poulan Deluxe Super 25 Chainsaw Manual

The Poulan Deluxe Super 25 is a professional-grade chainsaw featuring a 25cc 2-cycle engine, 16-inch guide bar, automatic oiler, chain brake, anti-vibration system, and easy-start technology. This manual covers essential safety instructions, assembly, operation, maintenance, troubleshooting, and storage procedures to ensure safe and efficient use.

1. Safety Instructions 2. Parts Identification 3. Assembly & Setup 4. Specifications 5. Operation Controls 6. Starting & Stopping 7. Maintenance Schedule 8. Chain Sharpening & Tensioning 9. Fuel & Lubrication 10. Troubleshooting 11. Storage

Safety Instructions

Read all instructions before use. Wear protective gear: safety glasses, gloves, hearing protection, steel-toe boots, and chainsaw chaps.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; keep chain sharp; do not cut with tip.
Fuel Handling	Use outdoors only; no smoking; store fuel in approved container.
Electrical Lines	Check for overhead lines before cutting.
Fall Hazards	Do not operate on ladders or unstable surfaces.
Hot Surfaces	Avoid contact with muffler and engine during/after operation.

Parts Identification

Key components of the Poulan Deluxe Super 25 chainsaw.

Front Hand Guard / Chain Brake
Throttle Trigger Lockout
Throttle Trigger
Rear Handle
Starter Grip
Fuel Tank Cap
Oil Tank Cap
Guide Bar
Chain
Chain Tensioner
Muffler
Air Filter Cover

WARNING! Familiarize yourself with all controls before starting the engine.

Assembly & Setup

Unpack and assemble the chainsaw following these steps.

Attach Guide Bar & Chain: Place bar over studs, align chain with sprocket, fit chain around bar, tighten nuts.
Fill Oil Tank: Use recommended bar & chain oil; fill to indicated level.
Fuel Mix: Use fresh unleaded gasoline (87 octane min.) mixed with 2-cycle oil at 40:1 ratio (3.2 oz oil per 1 gal gas).
Check Chain Tension: Chain should snap back when pulled from bar; adjust tensioner screw if loose.

CAUTION! Ensure chain brake is disengaged (pulled back toward front handle) before starting.

Specifications

Engine: 25cc, 2-cycle, air-cooled.
Guide Bar Length: 16 inches.
Chain Pitch: 0.325 inch.
Chain Gauge: 0.050 inch.
Fuel Tank Capacity: 8.5 fl oz.
Oil Tank Capacity: 5.1 fl oz.
Weight (dry): 9.5 lbs.
Sound Power Level: 112 dB(A).
Vibration Level: Front Handle: 4.5 m/s²; Rear Handle: 6.2 m/s².

Operation Controls

Master the controls for safe and effective cutting.

On/Off Switch: I = ON, O = OFF. Choke Control: For cold starts. Throttle Trigger: Controls engine speed; must be used with lockout. Throttle Trigger Lockout: Prevents accidental throttle engagement. Chain Brake: Stops chain instantly if activated by hand or inertia. Chain Catcher: Helps reduce risk if chain breaks. Right-Hand Guard: Protects hand from broken chain.

Starting & Stopping

Follow proper procedure to start and stop the engine.

Cold Start: Set On/Off to I. Pull choke to full position. Press decompression valve (if equipped). Hold saw firmly on ground, engage chain brake. Pull starter rope briskly until engine fires. Push choke to half position. Pull starter again until engine runs. Push choke fully off.
Warm Start: Choke off. Follow steps without using choke.
Stopping: Release throttle. Set On/Off switch to O.

Tip: Always engage chain brake when starting or carrying the saw.

Maintenance Schedule

Regular maintenance ensures longevity and safety.

Interval	Task
Before each use	Check chain tension, sharpness, and lubrication. Inspect for loose parts.
Every 5 hours	Clean air filter. Check spark plug.
Every 10 hours	Clean cooling fins. Check fuel filter.
Every 20 hours	Replace spark plug. Clean muffler screen.
Seasonally	Replace fuel filter. Inspect bar for wear.

Chain Sharpening & Tensioning

Proper chain care is critical for performance and safety.

Tensioning: Loosen bar nuts. Turn tensioning screw clockwise until chain fits snug against bar (can be pulled by hand but snaps back). Tighten bar nuts while lifting tip of bar.
Sharpening: Use round file matching chain pitch (5/32" for 0.325"). File each cutter at 30° angle, maintaining original depth gauge. File all cutters evenly.

WARNING! Always wear gloves when handling chain. Stop engine and disconnect spark plug before maintenance.

Fuel & Lubrication

Use correct fuels and lubricants to prevent engine damage.

Fuel Mix: 40:1 ratio. Use high-quality 2-cycle engine oil meeting JASO FD or ISO-L-EGD standards. Bar & Chain Oil: Use clean, non-detergent oil with tackifiers. Storage: For long-term storage, drain fuel tank and run engine until it stops to clear carburetor. Store in dry place.

CAUTION! Never use straight gasoline or automotive motor oil. This will cause severe engine damage.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, old fuel, flooded	Check spark plug; use fresh fuel mix; wait if flooded.
Engine runs then dies	Clogged fuel filter, air filter	Replace fuel filter; clean air filter.
Chain doesn't turn	Brake engaged, clutch worn	Disengage chain brake; inspect clutch.
Excessive vibration	Loose parts, unbalanced chain	Tighten all nuts/bolts; sharpen chain evenly.
Chain throws oil	Oil port clogged, wrong oil	Clean oil ports; use correct bar oil.
Poor cutting performance	Dull chain, improper tension	Sharpen chain; adjust tension.

Service: For repairs, contact authorized Poulan service center.

Storage

Prepare chainsaw for storage to prevent damage and corrosion.

Clean entire saw of dirt, sawdust, and resin.
Drain fuel tank completely. Run engine until it stops to use up fuel in carburetor.
Remove chain, clean in solvent, dry, and coat with oil.
Store in dry, cool place, away from children and sources of ignition.

CAUTION! Never store with fuel in tank for more than 30 days. Fuel can degrade and damage engine components.