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HELP! Weird Messed Up Poulan Recoil SetUp, help?

LAWN BOY

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I just bought a 1976 bicentennial Poulan chainsaw. The recoil setup is strange and really messed up. I’ve never worked on such a setup before. If anyone has any tips for me as to how to reassemble/fix this unit let me know. I would greatly appreciate it. Thanks for your time.
 

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LAWN BOY

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I got this far with reassembly and untangling. But I think the end of the spring that I circled in red is broken, right?
 

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hacskaroly

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But I think the end of the spring that I circled in red is broken, right
Not sure if what I found is similar to your saw, but it is a diagram for a Model 76 Poulan chainsaw. This spring does show a loop on the end, it appears to fit on a spot on item #34. Hope this helps.

Untitled.png
 

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Not sure if what I found is similar to your saw, but it is a diagram for a Model 76 Poulan chainsaw. This spring does show a loop on the end, it appears to fit on a spot on item #34. Hope this helps.

View attachment 410770
Yes, this is a Poulan 76. Thanks. That means that my spring is broken so I’ll order a new one.
 

hacskaroly

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Does this look correct so far?
That may work for a while, not sure if through use it will slip back in or break off. From the service manual image, it looks like it may feed back through to create resistance or maybe even tack welded back to the spring to create a loop to prevent it from slipping back through.

Untitled.png
 

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LAWN BOY

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Update. Just got the rope in the pulley kinda. Greased the bearing a bit. I’m not understanding the manual. How much inches of rope is needed? I have too much.
 

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hacskaroly

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How much inches of rope is needed?
Typically I cut 42 inches, fit the rope through the hole in the case/cover, put on the handle and tie the other end off to the pulley. Get it all fit into place, wind the rope around the pulley three times, then holding the rope against one spot on the pulley, rotate the pulley around three full turns to load up the spring. Once here, feed any remaining rope through the hole so no rope will hang up. Release the pulley to suck back in the rope. If the handle doesn't rest tightly against the case/cover then you may need to untie the handle, pull the rope out a little and then retie the handle at a new spot. Once you get it to where you need it, trim the rope and burn the end.

 

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Oops, I think I put the spring in the wrong way… Do I need to redo this? Here are pictures of it and in the manual…
The manual says 7-9 inches of rope, that can’t be right…?
 

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Czed

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Oops, I think I put the spring in the wrong way… Do I need to redo this? Here are pictures of it and in the manual…
The manual says 7-9 inches of rope, that can’t be right…?
You'll have to reverse it
It's a one way winding spring.
 

LAWN BOY

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After a full hour of sweaty and hurting hands I finally got the spring back in properly. However, I realized I’m missing a spacer washer. So after I got that I should be ready to reassemble the saw.
 

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I’m not understanding how to prewind the spring and why. I got the washer that was missing. If someone could explain this to me farther I’d appreciate it.
 

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You want the rope wrapped up when in the resting position is why
 

LAWN BOY

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I think I finally got the spring prewound and such. Now I don’t know how to route the fuel line on this model. It would be so uptight to thhe flywheel…
 

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