Poulan Pro Chainsaw 42cc Manual

The Poulan Pro 42cc chainsaw is a gas-powered tool designed for demanding cutting tasks, featuring a 42cc 2-cycle engine, 18-inch guide bar, automatic oiler, anti-vibration system, and easy-start technology. This manual covers essential safety procedures, assembly instructions, operation guidelines, maintenance schedules, troubleshooting, and warranty information to ensure safe and efficient use.

1. Safety Information 2. Parts Identification 3. Assembly Instructions 4. Fuel & Oil 5. Starting & Stopping 6. Operating Procedures 7. Maintenance 8. Chain Sharpening 9. Storage 10. Troubleshooting 11. Specifications & Warranty

Safety Information

Read all instructions before operation. Always wear protective equipment: safety glasses, hearing protection, gloves, chainsaw chaps, and steel-toe boots.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; do not cut with tip of bar.
Fuel Handling	Refuel in well-ventilated area with engine off and cool.
Electrical Lines	Stay at least 10 feet away from overhead power lines.
Fall Hazards	Do not operate on ladders or unstable surfaces.
Bystanders	Keep people and pets at least 15 feet away.

WARNING! Failure to follow safety instructions can result in serious injury or death.

Parts Identification

Key components of the Poulan Pro 42cc chainsaw.

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

Assembly Instructions

Assemble the chainsaw before first use.

Attach Guide Bar & Chain: Place bar over studs, align chain with drive sprocket and bar groove, install bar nuts finger-tight.
Tension Chain: Loosen bar nuts, turn tensioning screw clockwise until chain fits snug against bar, tighten bar nuts.
Check Chain Lubrication: Fill oil tank with bar and chain oil.
Fuel Mix: Prepare 2-cycle fuel (40:1 gas to oil ratio).

CAUTION! Ensure chain is properly tensioned—too tight can damage saw; too loose can derail.

Fuel & Oil

Fuel Type: Unleaded gasoline with minimum 89 octane.
Oil Mix: High-quality 2-cycle engine oil at 40:1 ratio (3.2 oz oil per 1 gallon gas).
Bar & Chain Oil: Use SAE 30 or special chainsaw oil.
Refueling: Stop engine and allow to cool. Wipe area clean. Use funnel to avoid spills.
Storage: Do not store fuel mix more than 60 days.

WARNING! Never use automotive oil or straight gasoline. This will damage engine.

Starting & Stopping

Cold Start Procedure:

Place saw on flat, clear ground.
Engage chain brake by pushing hand guard forward.
Set choke lever to FULL CHOKE position.
Press primer bulb 5-6 times until fuel is visible.
Pull starter rope briskly 2-3 times until engine "pops".
Move choke lever to HALF CHOKE.
Pull starter rope until engine starts.
Allow to warm up 30 seconds, then squeeze throttle to disengage choke.

Stopping: Release throttle, push STOP switch to OFF position.

Operating Procedures

Basic Cutting Techniques:

Firm Grip: Hold rear handle with right hand, front handle with left hand.
Stance: Stand with feet shoulder-width apart, left foot slightly forward.
Starting Cut: Let chain reach full speed before contacting wood.
Buck Cutting: Support log off ground; cut from top down.
Limbing: Cut branches from bottom to top of fallen tree.
Kickback Prevention: Never cut with upper tip of guide bar.

Tip: Let the saw do the work—do not force it through the cut.

Maintenance

Regular maintenance ensures optimal performance and longevity.

Interval	Task
Before each use	Check chain tension, sharpness, and lubrication.
Every 5 hours	Clean air filter; check for damage.
Every 10 hours	Clean spark arrestor screen in muffler.
Every 20 hours	Replace spark plug (gap 0.025 inch).
Seasonally	Inspect fuel lines, filters, and anti-vibration mounts.

CAUTION! Always disconnect spark plug wire before performing maintenance.

Chain Sharpening

A sharp chain cuts faster and safer.

Secure saw: Use vise to hold bar firmly.
File size: Use 5/32" round file for standard chain.
Angle: Maintain 30° filing angle; follow existing angle on cutter.
File strokes: Apply equal pressure on forward strokes; 2-3 strokes per cutter.
Depth gauges: Use flat file to lower rakers to proper height (0.025" below cutter).
Equal sharpening: Sharpen all cutters to same length.

WARNING! Wear heavy gloves when handling chain.

Storage

Proper storage prevents fuel system issues.

Drain fuel tank and run engine until it stops to clear carburetor.
Remove chain, clean in solvent, coat with oil and store separately.
Clean entire saw of dirt, sap, and debris.
Store in dry, cool place away from ignition sources.
Cover saw to prevent dust accumulation.

CAUTION! Never store saw with fuel in tank for extended periods.

Troubleshooting

Problem	Possible Cause	Solution
Engine won't start	No spark, old fuel, clogged filter	Check spark plug; use fresh fuel mix; clean air filter.
Engine runs then dies	Fuel line clogged, vent blocked	Clean fuel filter and tank vent.
Chain doesn't turn	Brake engaged, clutch worn	Disengage chain brake; inspect clutch.
Excessive vibration	Loose parts, damaged mounts	Tighten all bolts; check anti-vibration mounts.
Chain throws oil	Overfilled oil tank	Drain to proper level; check oiler adjustment.
Poor cutting performance	Dull chain, improper tension	Sharpen chain; adjust tension.

Specifications & Warranty

Engine: 42cc 2-cycle air-cooled
Bar Length: 18 inches
Chain Pitch: 3/8" low-profile
Fuel Capacity: 14.9 fl oz (440 ml)
Oil Capacity: 8.5 fl oz (250 ml)
Weight: 12.1 lbs (5.5 kg) without bar & chain
Sound Level: 106 dB(A) at operator's ear
Warranty: 2-year limited warranty for residential use

For technical support or warranty service, contact Poulan Pro at 1-800-554-6723 or visit www.poulanpro.com. Keep your proof of purchase.