Solo 636 Chainsaw Manual

The Solo 636 is a professional-grade chainsaw designed for demanding forestry and arborist work. Featuring a powerful 63.6cc two-stroke engine, advanced anti-vibration system, automatic chain oiler, quick-stop chain brake, and ergonomic design for extended use. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: 63.6cc SOLO two-stroke engine, 20-inch guide bar, automatic chain oiler, inertia-activated chain brake, decompression valve, anti-vibration system, translucent fuel tank.

Feature	Description
Engine displacement	63.6cc two-stroke air-cooled engine
Guide bar length	Standard 20-inch (50cm) Oregon bar
Chain type	.325-inch pitch, 72 drive links
Automatic oiler	Adjustable flow rate for bar/chain lubrication
Chain brake	Inertia-activated safety brake
Anti-vibration	Damped handle system reduces operator fatigue
Decompression valve	Easier starting with reduced cylinder pressure
Fuel capacity	0.95 liter (0.25 gallon) translucent tank
Oil capacity	0.32 liter (0.085 gallon) chain oil tank
Weight (powerhead)	6.8 kg (15 lbs) without bar and chain

Safety Instructions

Always wear proper PPE: helmet with face shield, hearing protection, chainsaw chaps, gloves, and steel-toe boots.

1. Clear work area of obstacles and bystanders.
2. Inspect chainsaw before each use: chain tension, sharpness, lubrication.
3. Always engage chain brake when carrying or not cutting.
4. Use proper cutting techniques: avoid kickback zone (upper quarter of bar tip).
5. Never operate above shoulder height or on unstable footing.

WARNING! Chainsaw kickback can cause severe injury. Always maintain firm grip and proper stance.

Assembly & Preparation

Unpack and inspect all components. Assembly requires mounting bar and chain, filling fluids.

1. Mount guide bar: Loosen bar nuts, position bar on studs, align chain groove.
2. Install chain: Place chain over sprocket and bar, ensure cutting teeth face forward.
3. Adjust tension: Tighten bar nuts hand-tight, adjust tension screw until chain snaps back when lifted.
4. Final tighten: Secure bar nuts to 9-11 Nm torque.
5. Fill fluids: Use fresh 50:1 fuel/oil mix (89+ octane); fill chain oil with SAE 30 bar oil.

CAUTION! Never use automotive oil or old gasoline. Mix fuel in approved container.

Specifications

• Engine: 63.6cc SOLO two-stroke, air-cooled.
• Power output: 4.2 kW (5.6 hp) at 9,500 RPM.
• Fuel: 50:1 mix (89 octane gasoline with JASO FD/ISO-L-EGD certified oil).
• Idle speed: 2,800 RPM.
• Maximum power speed: 9,500 RPM.
• Spark plug: NGK BPMR7A, gap 0.5mm.
• Sound pressure: 112 dB(A) at operator's ear.
• Vibration levels: Front handle 4.2 m/s², rear handle 3.8 m/s².
• Warranty: 2 years commercial, 5 years private use.

Controls and Components

Main controls: Front handle with throttle trigger lockout, rear handle with throttle trigger, choke lever, decompression valve, master control lever (stop switch), chain brake lever.

Components: Chain catcher, right-hand guard, muffler with spark arrestor, translucent fuel tank, adjustable oiler, side-access chain tensioner, air filter cover.

Operation: Master control lever has three positions: RUN (normal operation), STOP (engine off), CHOKE (cold start). Chain brake engaged by pushing forward guard; disengaged by pulling back toward rear handle.

Starting Procedure

Cold start and warm start procedures differ. Always engage chain brake before starting.

1. Place on flat, clear surface. Engage chain brake.
2. Cold start: Set master control to CHOKE. Pull starter rope 3-5 times until engine fires.
3. Move master control to RUN. Pull starter until engine starts.
4. Warm start: Set master control directly to RUN. Pull starter.
5. Allow 30-second warm-up at idle before disengaging chain brake.

Tip: Use decompression valve for easier starting—press button before pulling starter.

Operation Guidelines

Proper cutting techniques maximize efficiency and safety.

1. Felling: Use notch and backcut method. Plan escape path at 45° angle.
2. Limbing: Work from trunk outward. Keep saw between you and branch.
3. Bucking: Support log properly. Use top of bar for cutting, avoid ground contact.
4. Kickback prevention: Maintain firm grip, never cut with bar tip, keep chain sharp.
5. Oiling check: Verify oil discharge by pointing bar tip at light surface at idle.

WARNING! Never cut with dull chain—increases kickback risk and operator fatigue.

Maintenance Schedule

Daily: Clean air filter, check chain tension/sharpness, inspect bar for wear, verify oiler function.

Weekly: Clean spark arrestor screen, check spark plug gap, clean cooling fins, inspect anti-vibration mounts.

Monthly: Replace fuel filter, clean carburetor air passage, check clutch drum and sprocket.

Annually: Replace spark plug, fuel lines, impulse line. Professional carburetor adjustment recommended.

Chain & Bar Care

Regular maintenance extends bar and chain life.

1. Sharpening: Use 4.0mm round file at 30° angle. Maintain consistent depth gauge height.
2. Rotation: Flip bar weekly to ensure even wear.
3. Cleaning: Remove bar, clean groove and oil holes with wire.
4. Inspection: Check for hooked edges, uneven wear, or heat discoloration.
5. Replacement: Replace chain when cutters are 50% worn; replace bar when groove width exceeds 1.3mm.

CAUTION! Always wear gloves when handling chain—cutting edges are sharp.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

1. Short-term (under 30 days): Drain fuel tank, run engine until carburetor is dry.
2. Long-term: Remove spark plug, add 1 teaspoon of oil to cylinder, pull starter slowly to coat.
3. Clean entire saw, apply light oil to bar and chain.
4. Store in dry place, cover to prevent dust accumulation.
5. Before reuse: Refill with fresh fuel, check all components.

WARNING! Never store with fuel in tank—causes varnish buildup in carburetor.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Old fuel, flooded, spark plug	Use fresh fuel; wait 15 min if flooded; check/replace spark plug.
Engine runs then dies	Fuel filter clogged, vent blocked	Replace fuel filter; clean tank vent.
Chain won't turn	Brake engaged, clutch worn	Disengage chain brake; inspect clutch springs and shoes.
Poor cutting performance	Dull chain, improper tension	Sharpen chain; adjust tension per manual.
Excessive vibration	Loose components, worn mounts	Tighten all fasteners; replace anti-vibration elements.
Chain not oiling	Empty oil tank, clogged ports	Fill oil tank; clean oil holes in bar; adjust oiler screw.

Service: Authorized SOLO service centers only. Use genuine SOLO parts.

Support: 1-800-665-2455; www.solousa.com