Poulan Pro 16 Chainsaw Manual

The Poulan Pro 16 is a 16-inch gas-powered chainsaw designed for homeowners and DIY enthusiasts. It features a 42cc 2-cycle engine, automatic oiler, tool-less chain tensioning, inertia-activated chain brake, anti-vibration system, and a low-kickback bar and chain. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

1. Safety Information 2. Features & Specifications 3. Assembly & Setup 4. Controls & Operation 5. Fuel & Oil 6. Chain & Bar Maintenance 7. Starting Procedure 8. Cutting Techniques 9. Storage & Winterization 10. Troubleshooting 11. Warranty & Support

Safety Information

Critical safety warnings and personal protective equipment (PPE) requirements.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; use low-kickback chain; avoid tip contact.
Hearing Damage	Always wear hearing protection (ear muffs/plugs).
Eye Injury	Wear safety glasses or face shield.
Leg Injury	Wear cut-resistant chaps or pants.
Hand Vibration	Take frequent breaks; use anti-vibration gloves.
Fuel Fires	Refuel in well-ventilated area; engine must be cool.
Carbon Monoxide	Operate outdoors only; never in enclosed spaces.
Chain Brake Test	Test before each use by engaging brake with saw off.

WARNING! Failure to follow safety instructions can result in serious injury or death. Read manual completely before use.

Features & Specifications

Engine: 42cc 2-cycle air-cooled gasoline engine.
Bar Length: 16 inches (40 cm).
Chain Pitch/Gauge: 0.325” / 0.050”.
Fuel Capacity: 10.1 fl oz (300 ml).
Oil Capacity: 6.8 fl oz (200 ml).
Weight: 10.1 lbs (4.6 kg) without fuel/oil.
Ignition: Electronic ignition with stop switch.
Oiling System: Automatic chain oiler with manual override.
Chain Brake: Inertia-activated for kickback protection.
Vibration Dampening: Anti-vibration handles.

Assembly & Setup

Unpack and inspect all parts. Assembly requires bar, chain, and handle installation.

Attach Handle: Secure front and rear handles with provided bolts.
Install Bar & Chain: Place bar over studs, loop chain over sprocket and bar groove, adjust tension.
Chain Tensioning: Use tool-less side knob to tighten chain until snug against bar (pull up slightly in middle).
Add Fuel & Oil: Fill fuel tank with 50:1 gas/oil mix. Fill oil reservoir with bar & chain oil.
Check Controls: Ensure throttle trigger, throttle lockout, and chain brake function properly.

CAUTION! Wear gloves during assembly. Chain is sharp.

Controls & Operation

Key controls located on saw body and handle.

Control	Function
Throttle Trigger	Engages engine; releases to idle.
Throttle Lockout	Must be pressed before throttle trigger.
Stop Switch	Stops engine; set to "I" for ON, "O" for OFF.
Choke Lever	Used for cold starts.
Primer Bulb	Pumps fuel into carburetor for easier starting.
Chain Brake Lever	Engages brake when pushed forward.
Chain Oil Pump	Manual override button for extra oiling.
Side Tension Knob	Tool-less chain tension adjustment.

Fuel & Oil

Use fresh unleaded gasoline with minimum 89 octane. Mix with 2-cycle engine oil at 50:1 ratio.

Fuel Mix: 2.6 oz (77 ml) of oil per 1 gallon of gas.
Bar & Chain Oil: Use SAE 30 or special chainsaw oil. Do not use waste oil.
Refueling: Stop engine and let cool. Wipe area clean. Use funnel to avoid spills.
Oil Adjustment: Automatic oiler rate can be adjusted via screw near oil cap.

WARNING! Gasoline is flammable. No smoking. Store fuel in approved container.

Chain & Bar Maintenance

Regular maintenance ensures optimal performance and safety.

Chain Sharpening: Use round file (5/32”) and file guide. Maintain 30° cutting angle.
Depth Gauge: File rakers (depth gauges) to 0.025” below cutter.
Bar Care: Flip bar weekly for even wear. Clean bar groove and oil holes.
Sprocket Inspection: Replace if worn or damaged.
Tension Check: Chain stretches when new. Re-tension after first 10 minutes of use.

Tip: Keep chain sharp; a dull chain increases kickback risk and reduces cutting efficiency.

Starting Procedure

Follow steps carefully to avoid injury.

Cold Start: Place saw on flat ground. Engage chain brake. Set stop switch to "I". Pull choke lever out. Press primer bulb 5 times. Pull starter rope until engine fires (1-2 pulls). Push choke lever in. Pull starter rope to start.
Warm Start: Do not use choke. Press primer bulb 2-3 times. Pull starter rope.
After Starting: Let engine warm up 30 seconds. Squeeze throttle to disengage fast idle. Release chain brake before cutting.

CAUTION! Keep bystanders 15 feet away. Ensure chain is clear of objects.

Cutting Techniques

Proper stance and technique reduce fatigue and risk.

Stance: Feet shoulder-width apart, firm footing.
Grip: Left hand on front handle, right on rear, thumbs wrapped.
Kickback Zone: Avoid cutting with upper quarter of bar tip.
Bucking: Cut logs from top side. Support log off ground.
Limbing: Cut branches from bottom to top. Watch for springback.
Felling: Not recommended for inexperienced users. Consult professional.

WARNING! Never operate above shoulder height. Do not cut with one hand.

Storage & Winterization

Prepare saw for long-term storage.

Drain fuel tank and run engine until it stops to clear carburetor.
Remove chain, clean, and soak in oil. Clean bar and sprocket.
Wipe entire saw clean of dirt, sap, and debris.
Store in dry place, covered, out of reach of children.

CAUTION! Storing with fuel can cause carburetor damage. Use fuel stabilizer if storing less than 30 days.

Troubleshooting

Problem	Possible Cause	Solution
Engine won't start	Old fuel, flooded engine, spark plug	Use fresh mix; wait 15 min if flooded; check/replace spark plug.
Engine runs then dies	Clogged fuel filter, air filter	Replace fuel filter; clean air filter.
Chain won't turn	Brake engaged, clutch, sprocket	Disengage brake; check clutch drum/sprocket.
Chain throws oil	Over-oiling, wrong oil	Adjust oiler rate; use correct bar oil.
Excessive vibration	Loose parts, damaged bar	Tighten all bolts; inspect bar for wear.
Poor cutting performance	Dull chain, low chain tension	Sharpen chain; adjust tension.

Warranty & Support

Poulan Pro 16 chainsaw includes a 2-year limited warranty for residential use. Proof of purchase required. Warranty does not cover wear items (chain, bar, spark plug, filters) or damage from misuse, neglect, or improper fuel.

Customer Support: 1-800-554-6723

Online: www.poulanpro.com

Parts & Manuals: www.poulanpro.com/parts

Safety Videos: Available on official YouTube channel.