Chainsaw Repair

Husqvarna - Stihl - Poulan - Jonsered - Dolmar chainsaws and more => Poulan => Topic started by: Cut4fun on February 27, 2011, 06:38:30 pm


Title: Poulan 415
Post by: Cut4fun on February 27, 2011, 06:38:30 pm
Here is a PP 415 I bought as a box of parts after a tree broke the crankcase. Last owner had the same broken area on crankcase as the 475. He tried to have it welded, but it did hold. plus it made the metal even more brittle there and left a hole for me to repair when I did my redneck fix.

(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415001.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/415003.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Projectsaws023.jpg)


This is it still needing a carb kit after putting it back together. Just some soft year old poplar and pushing hard to check to make sure my redneck fix would hold.

http://www.youtube.com/watch?v=HsfKQxs6KZI

Title: Re: Poulan Pro 415
Post by: sharkey on April 08, 2011, 04:12:30 pm
Man that 415 is hauling after that carb soak!
Title: Re: Poulan Pro 415
Post by: David Young on April 16, 2011, 12:14:33 am
what does the cylinder look like is it the same as teh 475 and 505?what does that one like to run stock?
Title: Re: Poulan Pro 415
Post by: Cut4fun on April 16, 2011, 10:45:12 am
David, put it this way Jerry Gingras runs a stock appearing 475 with ( what I would guess would be a ) 505 top end. Legal right down to the correct cc for a 5ci.

 Now my mind isnt what it used to be, but pretty sure.  Pics are here of the 505 cylinder. 415 475 should look similar.

Watch the webster wv 5ci 2010 video of the yellow poulan jerry is running.
Title: Re: Poulan Pro 415
Post by: Cut4fun on April 16, 2011, 10:46:23 am
505   http://chainsawrepair.createaforum.com/poulan/poulan-projects/?action=dlattach;attach=37;image
http://chainsawrepair.createaforum.com/poulan/poulan-projects/?action=dlattach;attach=27;image
http://chainsawrepair.createaforum.com/poulan/poulan-projects/?action=dlattach;attach=39;image
Title: Re: Poulan Pro 415
Post by: Cut4fun on April 16, 2011, 11:13:02 am
415 pics, none before cyl bolted on. Carbs are WJ on all of them I have seen.

(http://i59.photobucket.com/albums/g289/doemaster789/415/CopyofDSCF0058.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/CopyofDSCF0057.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/CopyofDSCF0055.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415008.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415004.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415005.jpg)

Title: Re: Poulan Pro 415
Post by: Cut4fun . on April 16, 2011, 02:49:32 pm
DY, I just took a top off a savable P+C from a 475 if you need better pics.
Title: Re: Poulan Pro 415
Post by: David Young on April 16, 2011, 03:10:10 pm
I am putting together a 2083 now most of the work is done. I did some mild porting to it and I am looking forward to running it in the next week or so. I did get rid of that nasty looking green ignition. It was really clashing against the red and black color scheme so I put a black one in instead.  Well I am piecing this together from three saws most of the parts came from a 2077 that had the case broke like your was but by a tree I believe. Any way I have seen the 77 and the 83 I just wanted to see if the little brother was the same?  I may need a front handle and misc parts but I also have a bunch of red and black parts fyi. So do you think the 2083 will pair better with the 590 or the 2055? :). Or do you think it would be more at home with a 5000 p70 and one of the p100's? ;).  I can tell you this there is a lot of the 2077 in the 372. Probably more then people realize.
Title: Re: Poulan Pro 415
Post by: Cut4fun . on April 16, 2011, 03:23:44 pm
415 crankcase was broke by a tree.  475 crankcase was broke due to a lazy shipper putting the PHO in a empty box.

Are you the one that bought the 2083 and 2077 on ebay? Also is your 2083 the 82cc bore or smaller II 77cc?

Title: Re: Poulan Pro 415
Post by: David Young on April 17, 2011, 11:56:33 am
I haven't bought anything in quite a while, I am going through a divorce and I need to actually go the other way and get rid of stuff, no basement, no garage.  I have had these parts for 3-4 years and I am just putting this together now.  I have the 82cc top on there now on a 2083 bottom it has the eco oiler, decomp and air injection.  I have the makings for this to be a 2077, top end different crank and oiler.  I'll get some pics up soon, maybe a vid if the saw runs well, I hope I don't need a carb kit.

David
Title: Re: Poulan Pro 415
Post by: Cut4fun . on May 10, 2013, 06:14:15 pm
Just comparing my poulan pro 415 yellow  air filter cover to the partner yellow covers. My 415 was bought new with these covers shown on it at TSC. Still the only one I have seen to date with yellow cover in US.  :o
Just thinking of looking for a partner yellow cylinder cover to match.


PP415

(http://i59.photobucket.com/albums/g289/doemaster789/415/CopyofDSCF0058.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415005.jpg)


Partner 660 710 7700 etc

(http://i59.photobucket.com/albums/g289/doemaster789/415/6607700a.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/6607700.jpg)

Title: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 11:48:57 am
Poge has a early poulan pro 415 to show differences in the early like 475 and the later 415.

His has the air filter set up like the PP475 and grey bar OEM. Mine came with updated air filter like on the 425 445 505 and black bar with yellow lettering.

Working on pics.

Early Poge 415

Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 12:02:30 pm
My 415 is 92 also. So somewhere in that year they made the updated change to mine.

(http://i59.photobucket.com/albums/g289/doemaster789/415/475425007.jpg)


Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 12:06:42 pm
@SawTroll  or anyone else that remembers. can you tell week made etc on those tags on 415?
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 12:09:57 pm
Our 415 tanks and air filter covers are different too.
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 12:13:00 pm
My 415 with 425 445 505 air filter set up.

(http://i59.photobucket.com/albums/g289/doemaster789/415/CopyofDSCF0058.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415005.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/415003.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415008.jpg)
(http://i59.photobucket.com/albums/g289/doemaster789/415/Copyof415004.jpg)

Title: Re: Poulan 415 early later models
Post by: jeff.lary on September 13, 2015, 12:19:08 pm
Every time I see saws like these I kind of bugs me that they couldn't stay in business,.. man them were some sharp looking saws.
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 12:28:17 pm
Found this listed as being sold in 93

Chain Saws   Poulan   1993   PP415   
Engine Make:    Poulan
   
Engine Size Cubic Centimeters:    65
Engine Size Cubic Inches:    4
   
Dry Weight:    14.9
Bar Oiler Type:    Automatic
   
Bar Length:    16
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 02:25:55 pm
If read like the black husky tag. 92 week 7 and his is saw 20 and mine 254 so week 7 sometime in production must have been when they began switching  stuff WAG
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 02:28:26 pm
@PogoInTheWoods  I could be full of chit with my WAG here but this is what I am finding comparing.
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 13, 2015, 02:52:34 pm
These are dates I already posted here from 2012

Reading like a husky tag my guesses would be.  I have 3 445 and many 505 I could add and check now too.

425 = 1995

415 = 1992

475 = 1990 

505 = 1996
Title: Re: Poulan 415 early later models
Post by: 3000 FPS on September 14, 2015, 12:19:47 am
Kevin I see the air filter cover on yours is yellow and on poge it is grey.   Is the yellow correct on your saw and is that something that changed with the year it was made.
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 14, 2015, 12:20:33 pm
Yes the yellow came on my 415 when bought new from TSC by owner before me.  If you look at the partner saws in series they are both yellow also.

I have seen the yellow air filter cover for sale once NOS since I have owned mine.

Also dont know if I stated it already my 415 has the update to the coil spring AV.  Early poge 415  is rubber av like the 475.
Title: Re: Poulan 415 early later models
Post by: Cut4fun on September 14, 2015, 01:23:09 pm
(http://www.iggaaruhland.de/Kniffo/trio.jpg)
Title: Re: Poulan 415 early later models
Post by: Cut4fun on September 14, 2015, 01:25:24 pm
Thinking mine might have still had the older oiler drive worm gear and pto seal set up like on 475 and earlier 415. Not the updates like done on 425 etc.
Title: Re: Poulan 415 early later models
Post by: Cut4fun on September 14, 2015, 01:36:36 pm
Here is a 1990 PP415 full wrap I was offered in trade for the 2095. But I had already received paypal for the jred earlier that day or I would have traded.
**** but have the parts.  :'(

Title: Re: Poulan 415 early later models
Post by: 3000 FPS on September 14, 2015, 05:31:05 pm
Nice, thanks Kevin.
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on September 15, 2015, 12:39:07 pm
Just so people that dont know. I wasnt talking about the different color of the 415 air filter cover as the change. It is how it is made inside for the updated air filters used in later 415 425 445 505.
It is how it is made to match the tanks also. Tanks are different for each air filter style.


Here is a 445 on left like the inside of my later 415 cover and a 475 like the earlier 415.   





Title: Re: Poulan 415
Post by: Cut4fun . on October 11, 2015, 07:12:40 pm
Love this saw even more every time I make a cut with it.  BIG  ;D s

https://youtu.be/Kx2U5HAIfeQ
Title: Re: Poulan 415
Post by: Cut4fun . on October 28, 2015, 01:45:49 pm
Got a good laugh at work. Friend that cuts wood for heat.
Right now he runs a 272 and said he is going to buy a new stihl 391. I laughed at him and ask why he is going backwards to a plastic saw. I know it runs and cuts good as I take care of the smaller 311 saws here for guys.

But then he made the comment. Better then your poooouuloooon  :o. I laughed again and said bring it I will even run my smallest matching cc poulan the PP415.

Boy oh boy he just opened a can of whoop azz.  :D
Title: Re: Poulan 415
Post by: 3000 FPS on October 28, 2015, 10:24:26 pm
I love it Kevin.   A 445 would be even better.
Title: Re: Poulan 415
Post by: acornhill on December 29, 2015, 07:03:41 pm
Well i started the 415 today and it runs ok but is having trouble idling, it will idle for 2 minutes and dies out. It will start back up but will not idle for long by itself. I have the idle set on the highest point, also the L screw does not seem to do much. Any thoughts?
Title: Re: Poulan 415
Post by: Cut4fun . on December 29, 2015, 09:01:13 pm
Did you happen to check the seals etc?
Title: Re: Poulan 415 early later models
Post by: Cut4fun . on December 29, 2015, 09:10:54 pm
@acornhill  which air filter set up? early or later
Title: Re: Poulan 415 early later models
Post by: acornhill on December 29, 2015, 09:24:21 pm
Yup mine is early model, now please give me pointers to fine tune it. It will run and idle for about two minutes by itself. Starts right back up. Does the impulse line need check valves etc.
Title: Re: Poulan 415
Post by: acornhill on December 29, 2015, 10:33:49 pm
I did not do a vacuum test on it, I did turn the saw on its side and upside down and it did not
Change idle speed.
Title: Re: Poulan 415
Post by: 3000 FPS on December 30, 2015, 11:37:06 am
Have you replaced the fuel line and fuel filter.   I had a fuel filter do that one time to me and really faked me out.
Title: Re: Poulan 415
Post by: Cut4fun on December 30, 2015, 02:13:54 pm
please give me pointers to fine tune it. It will run and idle for about two minutes by itself. Starts right back up. Does the impulse line need check valves etc.

no checks.

did you say you put a new carb rebuild kit in it?
Title: Re: Poulan 415
Post by: Cut4fun . on January 30, 2016, 05:34:49 pm
Stock poulan 415 65cc trying to pull a 3/8 8T and aggressive chain I filed for a 3120 long ago.
Was hoping the pine cant would be forgiving with me pushing on it.  :P

https://youtu.be/cBCkLC2ovpc
Title: Re: Poulan 415
Post by: acornhill on January 31, 2016, 04:47:28 pm
please give me pointers to fine tune it. It will run and idle for about two minutes by itself. Starts right back up. Does the impulse line need check valves etc.

no checks.

did you say you put a new carb rebuild kit in it?
I did rebuild the carb but may need to go back in and set the metering height to flush with top of metering deck. I set it to flush with carburetor top

Sent from my LG-D800 using Tapatalk

Title: Re: Poulan 415
Post by: Cut4fun . on February 01, 2016, 12:40:14 pm
please give me pointers to fine tune it. It will run and idle for about two minutes by itself. Starts right back up. Does the impulse line need check valves etc.

no checks.

did you say you put a new carb rebuild kit in it?
I did rebuild the carb but may need to go back in and set the metering height to flush with top of metering deck. I set it to flush with carburetor top

Sent from my LG-D800 using Tapatalk



I dont remember the right setting off hand. Do you?
You need me to check my book or a carb I have off?
Title: Re: Poulan 415
Post by: acornhill on February 29, 2016, 09:48:57 pm
i finally went back in the 415 carburetor and reset the metering lever to flush with metering ceiling. I am now ready to run her again. I did the same thing to the PP525 i have and that saw is a beast now. It is amazing that moving the lever height such a small amount can make such a big difference.
Title: Re: Poulan 415
Post by: Cut4fun . on June 05, 2016, 04:46:29 pm
Here is the extra small dawg installed on my poulan 415. It is perfect for using the shorter bar IMO.

The extra small laid on top of the small one to compare them.


(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=200.0;attach=18514;image)
(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=200.0;attach=18515;image)
Title: Re: Poulan 415
Post by: Cut4fun . on January 16, 2017, 07:47:45 pm
While buying the NOS poulan parts today.

The dealer said he had a poulan 415 with the old style tank and air filter set up setting on the bench. Customers saw.

I was offered it today too. So Now I have another 415 coming in.  So it will be getting the updated tank and air filter set up like on the 505. ;)

Title: Re: Poulan 415
Post by: 3000 FPS on January 16, 2017, 08:50:22 pm
I know you like those saws.
Title: Re: Poulan 415
Post by: Cut4fun on January 17, 2017, 01:06:59 pm
Has the typical issues with this series when rode hard.  Jerked in the cuts, pushed down on and maybe a drop.

6 pics I was shown

Title: Re: Poulan 415
Post by: 3000 FPS on January 17, 2017, 07:59:41 pm
Yep It sure has seen a little miss use.    But still I know you will make it into a good running work saw.   
Title: Re: Poulan 415
Post by: Cut4fun . on January 18, 2017, 12:06:39 pm
65cc top will get pulled in time after testing out. Just not sure which top I put back. Leaning toward a 445.

Was thinking of pulling the 505 off the wild thing for another 445. Butttttt now.


Still getting parts off the shelves and out of bins for the 475 a guy wants to build.  Need to split the 2 475 crankcases and pull the good crank for the better crankcase. Better crankcase has a big end rod bearing out. 

Title: Re: Poulan 415
Post by: Fishnuts2 on January 22, 2017, 08:53:50 am
I just bought a 415 and am anxious to run one.  However, it needs a clutch cover.
Does anyone here have one that I could purchase?
Thanks!
Title: Re: Poulan 415
Post by: Cut4fun on January 22, 2017, 10:15:43 am
I just bought a 415 and am anxious to run one.  However, it needs a clutch cover.
Does anyone here have one that I could purchase?
Thanks!


I would have to check. I know I just set one aside for a whole 475 in parts I am setting out for a possible buyer out of US.

Also you can make one out of a husky 268 272 etc clutch cover.  I've done it before and it works.
Title: Re: Poulan 415
Post by: Cut4fun . on January 27, 2017, 02:56:08 pm
I just bought a 415 and am anxious to run one.  However, it needs a clutch cover.
Does anyone here have one that I could purchase?
Thanks!


Just though of this too.

@Fishnuts2  if color dont matter. I have a Jred one I had painted orage and made a homemade sticker for a project saw I never finished.

You have the OUTSIDE metal plate that goes between the plastic cluch cover and bar I hope. They are a must on these IMO.

Pic below

Before
(http://i59.photobucket.com/albums/g289/doemaster789/Projects/j2095orange%20014_zpszjlzgn79.jpg)

After
(http://i59.photobucket.com/albums/g289/doemaster789/Projects/j2095orange%20018_zps32tvna7s.jpg)

Then some homemade decals
(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=2390.0;attach=14201;image)



Title: Re: Poulan 415
Post by: Cut4fun . on January 27, 2017, 03:08:04 pm
Heck even have the cover I made from a 268 husky cover.  Dont use it anymore either. Made it when I was 1 short.

(http://i59.photobucket.com/albums/g289/doemaster789/Partner550/barcoverdecals003_zpsc6ed2ca7.jpg)
Title: Re: Poulan 415
Post by: Cut4fun . on January 27, 2017, 03:11:07 pm
For the plastic cover you want this too 501444501 Bar Plate Outer

Price: $4.50  http://www.ereplacementparts.com/guide-plate-p-616879.html

Also on these

Husqvarna
61 (1980-02) Chainsaw
61 (1981-02) Chainsaw
61 (1982-05) Chainsaw
61 (1983-09) Chainsaw
61 (1984-01) Chainsaw
61 (1984-10) Chainsaw
61 (1985-06) Chainsaw
61 (1986-03) Chainsaw
61 (1986-12) Chainsaw
61 (1987-11) Chainsaw
61 (1988-06) Chainsaw
61 (1997-01) Chainsaw
66 (1987-06) Chainsaw
66 (1988-08) Chainsaw
66 (1989-02) Chainsaw
66 (1991-03) Chainsaw
298 (1987-01) Chainsaw
298 (1987-06) Chainsaw
266 (1981-09) Chainsaw
266 (1982-12) Chainsaw
266 (1983-06) Chainsaw
266 (1984-08) Chainsaw
266 (1984-10) Chainsaw
266 (1985-01) Chainsaw
266 (1985-06) Chainsaw
266 (1986-01) Chainsaw
285 (1981-12) Chainsaw
298 (1986-04) Chainsaw
162 (1980-02) Chainsaw
162 (1980-12) Chainsaw
2100 (1981-10) Chainsaw
2100 (1982-11) Chainsaw
2100 (1983-11) Chainsaw
2100 (1984-04) Chainsaw
2100 (1985-08) Chainsaw
2100 CD (1979-12) Chainsaw
2101 (1987-04) Chainsaw
2101 (1988-03) Chainsaw
2101 (1989-02) Chainsaw
2101 (1990-06) Chainsaw
Title: Re: Poulan 415
Post by: Fishnuts2 on January 27, 2017, 10:37:07 pm
Thanks for all your research!
I found one from a fellow that had lots of Jonsered parts. A little paint and I should good to go.


Sent from my iPhone using Tapatalk
Title: Re: Poulan 415
Post by: Cut4fun . on January 28, 2017, 11:43:21 am
Thanks for all your research!
I found one from a fellow that had lots of Jonsered parts. A little paint and I should good to go.


Sent from my iPhone using Tapatalk

If you get a chance to grab a poulan yellow metal or jonsered metal clutch cover = snag it.  I only have 1 of each.  Jred is NOS and the poulan is used from a 445.
Title: Re: Poulan 415
Post by: 3000 FPS on January 28, 2017, 11:57:49 pm
Even the plastic ones are not easy to come by.
Title: Re: Poulan 415
Post by: Fishnuts2 on January 31, 2017, 09:49:49 am
The one I bought is plastic and it came with the metal bar plate already on it.
He told me it was only one they had left too!


Sent from my iPhone using Tapatalk
Title: Re: Poulan 415
Post by: Fishnuts2 on March 01, 2017, 10:55:52 am
(https://uploads.tapatalk-cdn.com/20170301/b23736393a0497a57cdbcbb1a48ef6e7.jpg)(https://uploads.tapatalk-cdn.com/20170301/dcf492da3d7b3ae6be347c765397d292.jpg)
Got the 415 out for a cut this morning. It pulled this 24" nicely, but I have a 20" that's going on when the chain arrives. I also ordered a panel for the grip but won't be here for a couple weeks. Now to paint the clutch cover and off to surprise some farm boss operators!


Sent from my iPhone using Tapatalk
Title: Re: Poulan 415
Post by: 3000 FPS on March 01, 2017, 11:47:12 am
That saw will surprise more than a farm boss owner.   The 415 is one I do not own yet.   
Title: Re: Poulan 415
Post by: Cut4fun . on March 01, 2017, 12:50:00 pm
fishnut it should just laugh at a farmboss 290 or the new even smaller farmoss 270.  It better be kicking the 390 391 stihls with ease if it is running right.

My 415 is one of the strongest 64cc 65cc saws I have run to date.   Now that being said. I have yet to run a stock dolmar 6400 or solo 665.  Always wanted too but it has never worked out.

2x 415 and 1 425.   Roger if you can find the newer 425 would be the one to get. Updated like the 445 505. ;) But same cylinder as 415.
Title: Re: Poulan 415
Post by: Fishnuts2 on March 01, 2017, 10:10:28 pm
Yeah, I know about the 290's.  I've had a couple and have a 029S to fix up and sell.  But, I have a guy that I cut with once in awhile that looks down his nose at some of my saws as he starts his farm boss. 
I bought this saw just for his benefit and I can hardly wait!
Title: Re: Poulan 415
Post by: Cut4fun . on April 14, 2017, 08:35:16 pm
Started the last poulan 415 that come in finnally. Wanted to check it out before pulling the  tank etc off.

Put new side support and av handle support on it to sturdy up the broken tank handle areas.

 Somebody had used wire to hold the front av to the front handle mount to the side brace.  1 owner saw and even know the shop that sold it new to the guy.

Seems like she is going to be a good one.

One on right. 

Title: Re: Poulan 415
Post by: Cut4fun . on April 15, 2017, 11:44:28 am
Trying to decide if I want to leave this 65cc or take it up to 77cc.   Have a NOS set and 1 used set in 76.5cc 475 on the shelf. 

First need to tear it down and put the 505 tank set up on it and will see from there I guess.
Title: Re: Poulan 415
Post by: 3000 FPS on April 15, 2017, 02:10:18 pm
Trying to decide if I want to leave this 65cc or take it up to 77cc.   Have a NOS set and 1 used set in 76.5cc 475 on the shelf. 

First need to tear it down and put the 505 tank set up on it and will see from there I guess.

I would go with the 77cc set up.  Same weight but more power.
Title: Re: Poulan 415
Post by: Cut4fun . on April 15, 2017, 03:10:33 pm
Piston looks like new and inside cylinder so far. Sorry I suk at pics. IMO seems like a very low hour saw. Made 1991.
Ready to put a updated 505 tank and air filter set up after some cleaning.

Title: Re: Poulan 415
Post by: Cut4fun . on April 15, 2017, 07:38:03 pm
Thats more like it. The updated tank and air filter set up. Had to call it quits tonite. Beer time.

Front and rear of piston still had the witness lines and looked like new. So I left it 65cc.

If somebody wants the 415 475 air filter mesh and the used rubber tube and metal ring shown on tube still. $15 and shipping. The air filters are NLA new unless you find NOS. On LEFT bottom corner.
Title: Re: Poulan 415
Post by: Cut4fun . on April 16, 2017, 02:56:32 pm
 Done and just finished test cuts in some ash.
Only thing I did was leave the baffle out of the muffler on this one. Just badazz saws for 65cc IMHO. Quad ports.

415 425 same cylinder. Just 425 has all the updates done on them like 505. This is a 415 with 505 tank and filter set up.

Took this clutch cover pic to show a guy so he knows to get the outer metal bar plate and dont run it on these without. Unless he wants to fubarr his cover over time.

Title: Re: Poulan 415
Post by: 3000 FPS on April 16, 2017, 06:42:22 pm
Nice Job Kevin.
Title: Re: Poulan 415
Post by: Cut4fun . on April 16, 2017, 08:51:19 pm
That one loose outer bar plate shown above was on the 415 and was homemade. 
Title: Re: Poulan 415
Post by: Cut4fun . on October 24, 2017, 02:42:05 pm
Anyone recall what size the dang top cover bolts are. Need to order the helicoil or timesert kits to fix the case for top cylinder cover. 3 out of 4 stripped. The other is real close but usable.
Title: Re: Poulan 415
Post by: Cut4fun . on March 21, 2018, 05:53:46 pm
Just helping a guy out with a poulan needing a recoil.  Just happen to have some red I dont mind sending his way.

Title: Re: Poulan 415
Post by: Cut4fun on August 19, 2018, 03:33:48 pm
Hate seeing the little independent guys shop closing.
So I got what I really wanted and some I didnt really want.
He said the auction will be happening soon with what is left. Mostly mower stuff now.

Title: Re: Poulan 415
Post by: Cut4fun on August 20, 2018, 10:12:56 am
Not bad checking it over.  8)
Topend through plug hole looking at cylinder ext side looked sweet. 
Was missing 2 fasteners and 2 tank nuts on the upper left av mount  :o. Cant believe they didnt rip the right top cylinder handle av due to this.
3 wrong recoil fasteners = I have.
Missing tank handle insert = " ".  503427502
Looks like someone had made and rerun the  on/off wire to coil over time. Routed wrong which I will try and make right.
Oh the usual inner clutch cover deform I will fix later too.


 

Title: Re: Poulan 415
Post by: Cut4fun . on August 20, 2018, 01:51:18 pm
Grabbed some pics when passed through to get the mowers out. 
Title: Re: Poulan 415
Post by: 3000 FPS on August 20, 2018, 09:49:31 pm
Nice Kevin.
Title: Re: Poulan 415
Post by: Cut4fun . on August 23, 2018, 05:04:32 pm
Finally finished testing the PP415 65cc I picked up from a closing shop. Ran fine at full throttle in the cuts but couldnt get it to idle very long before it stopped. All the tuning in the world no help. So I started digging.
Suppose to have been ready to cut. He said he had been in the carb. Well maybe he was. But the fulcrum was bent side ways and the carb kit was getting real iffy.
So cleaned carb and put new kit in it. Still same problem.
Being I had a 2083 that I had just rebuilt the carb and knew it was known good I swapped it in. Good to go.
Figured the L side has some blockage somewhere.
65cc with 24" full comp buried in dry ash. 100% satisfied with it now.


Title: Re: Poulan 415
Post by: Cut4fun . on September 11, 2018, 02:40:20 pm
Calling it a day. 😎😋
Getting ready to meet someone halfway across Ohio with a few saws.
The PP415 that I just recently bought. Pulled the muffler to make sure even though looked through plug hole when I was checking things. Piston still has like new witness marks on the piston.



Title: Re: Poulan 415
Post by: Cut4fun . on October 06, 2018, 07:02:10 pm
Another find. Now this one is more to my liking.
Will be putting the full wrap and set of big dawgs I have on hand on WT505.

I got used to a full wrap on the 385 when I was running it with the 505. Sold the 385 and kept the 505.


Title: Re: Poulan 415
Post by: Cut4fun . on October 12, 2018, 03:46:11 pm
Full wrap 415 showed up today. No time to dig in. But looks like low usage for fire dept saw.

Crap chain and wrong bar mount =  D176. But hey they were close.

They had ground down the big dawg almost to the case due to bolting to the full wrap. Handel in great shape and all I cared about.    1990 and with older air filter and tank set up.

Title: Re: Poulan 415
Post by: Cut4fun . on October 13, 2018, 12:38:09 pm
Waiting it's turn in line. Paying saws first.



Title: Re: Poulan 415
Post by: Cut4fun . on October 13, 2018, 08:32:24 pm
Another 415 runner after quick check over.   
Replaced  plug, clutch bearing, washer and e-clip and  chain brake set up.  Was told reason they quit using it 2 years ago chain brake wouldn't work anymore.
Has the 505 worm gear in it instead of the metal 415 475 one.   Wonder if someone had done the 475 updated oiler set up. Still have 2 NOS ones.

Title: Re: Poulan 415
Post by: 3000 FPS on October 13, 2018, 09:31:01 pm
Congrats on another cool saw.
Title: Re: Poulan 415
Post by: Cut4fun . on October 13, 2018, 10:03:37 pm
Shame they cut the clutch cover for Fire dept use.  The metal outer plate was still there and the mount area on the cover was perfect.  Oh well make a good noodling cover or one for chip clearance if someone was racing.
Title: Re: Poulan 415
Post by: Cut4fun . on October 23, 2018, 02:58:45 pm
415 full wrap pulled for 505.
Now I got a guy wanting the tank for a 475.  hmmmmm  like the 425 445 505 tanks and air filter set ups better anyway. 





Title: Re: Poulan 415
Post by: Cut4fun on October 26, 2018, 09:19:46 am
Trying to decide which updated tank to put on this 415.  If and when the early tank on it gets pulled when sold.
Have them in red,  black and yellow.   

Already got 1 with yellow and 1 with black.  Only leaves red. But Roger done that already on a 505.


Title: Re: Poulan 415
Post by: 3000 FPS on October 26, 2018, 10:37:37 am
I just happen to use what worked.   The red ones are pretty common on ebay.
Title: Re: Poulan 415
Post by: Cut4fun . on October 26, 2018, 03:27:38 pm
I got the red and a black ready to put on as is.
The updated yellow one I would have to put all the parts in after a good cleaning.


I might just save it for the 415 that came with updated tank when new.




Title: Re: Poulan 415
Post by: 3000 FPS on October 26, 2018, 10:30:56 pm
The one thing I do know is that the color does not matter because the Red and Yellow one will out run all the others I have.   
Title: Re: Poulan 415
Post by: Cut4fun . on October 28, 2018, 01:01:03 pm
Even though this saw had no symptoms of anything wrong. Ran fine after just receiving it.
But was pulling tank for someone and noticed the intake side had started scoring. So pulled the muffler and just a little had started.
This saw was running the early 415 475 tank and early air filter system I dont care for. Guessing from ingest fines past air filter style is my best guess for ink side.

You seen what Bob had to say about the early air filter system?  = Bob Morrison I was involved in the development of that saw.   The original-style air filter on the 415 and 475 didn't work. Took me about two years to convince the Swedes of that.

Title: Re: Poulan 415
Post by: Cut4fun . on October 28, 2018, 02:00:00 pm
 Posted so Bob could see them. = Bob Morrison It surely brings back memories (nightmares) of saws that were failing in the field.

Bob Morrison Coincidentally, we had a Poulan/Weed Eater reunion last night. About 60 former employees showed up.
Title: Re: Poulan 415
Post by: Cut4fun . on November 01, 2018, 10:55:41 am
Thinking this 415 running  the updated plastic worm gear like 505 etc. Might become a 475.

Going to see if they used the updated worm kit like I bought NOS.


Updated yellow tank was the choice.

Used 475 cylinder and have the used piston and a NOS 475 piston kit left too.  I might just use that used piston I got from Roger on trade for a nos one. If the skirts are good to go and just clean that slight rub up.






Title: Re: Poulan 415
Post by: 3000 FPS on November 01, 2018, 11:27:35 am
Yep you could make it a 475.   You would have a bigger saw with pretty much the same weight.   
Title: Re: Poulan 415
Post by: Cut4fun . on November 01, 2018, 12:27:46 pm
Just saving pics for someone. A back up redneck repaired tank and handle I took in trade years ago on a NOS tank.
Now someone wants this plus some other NOS parts.
The prefilter is NLA new and most folks dont even know about them. Keeps the bigger chips from entering on the non air injection saws.
The fix the guy did is stronger then oem area. Well done.  ;)

 Poulan 503434101  Pre Cleaner

 Poulan 501269702 ANTIVIBE ELEMENT Standard upper

 Poulan 504125014  AV-RUBBER  Heavy Duty  upper

 Poulan 501814701  Shock Mount  lowers





Title: Re: Poulan 415
Post by: Cut4fun . on November 21, 2018, 12:39:18 pm
Just pulled the clutch on the last 415 to see if that had put the whole updated worm gear with the plastic worm gear I could see being used on it.

Yep, right drum, worm gear and the sleeve used to replace them on the metal worm gear etc with outer seal 415 475. 


Like one on left in old pic.





Title: Re: Poulan 415
Post by: Cut4fun . on December 13, 2018, 04:15:16 pm
1 more project trying to decide which way I am going with it. I sold the old early tank off it to help a shop with a 475 needing tank. So have the later updated tank ready. Just trying to decide between 415 or 445 cylinder.
Sold all my 475 topends and still have a 505 going. So they werent needed.

Still waiting on 1 more part for that dang 026. So working on some of mine.


Title: Re: Poulan 415
Post by: Cut4fun . on December 25, 2018, 02:02:59 pm
Husky Jred Partner Poulan folks might know this.
I always just used redneck tools in past to remove them. Looking for part # or numbers. The oem tool that is used to remove rubber anti vibes. Just for these 2 501269702 504125014 That 2 prong tools they make. Think maybe 3 total.

generic set https://www.ebay.com/itm/HUSQVARNA-61-266-268-272-ISSOLATOR-BUFFER-TOOL-FOR-501773401-AND-501773501/361535533388?hash=item542d32714c:g:S7UAAOSw-nZTrJAK

oem looks like this pic

Title: Re: Poulan 415
Post by: Cut4fun . on December 25, 2018, 02:56:30 pm
AV rubber damper
removal tool, 11 mm
For models: 61, 268, 272
Part. No. 502 50 67-01

AV rubber damper
removal tool, 14 mm
For models: 136, 141, 42,
242, 246, 61, 268, 272, 250R
Part. No. 502 51 00-02

AV rubber damper
removal tool, 18 mm
For models: 61, 268, 272,
288, 394, 3120
Part. No. 502 50 66-02

503554201   415 475 washer

503230014 has been superceded to 503230058  425 445 505 washer
Title: Re: Poulan 415
Post by: 3000 FPS on December 26, 2018, 08:15:39 pm
This Web site has a lot of good info stored in it now.
Title: Re: Poulan 415
Post by: Cut4fun . on December 30, 2018, 10:14:12 am
Paid for now to see if they are all 3 in stock. Pretty sure I only needed the 18mm for the 3 rubber av 415 475  poulans. 


502510002
Husqvarna U-Spanner 502510002
$6.99

502506602
Husqvarna U-Spanner 502506602
$6.99

502506701
Husqvarna U-Spanner 502506701
$6.99

$20.97
Subtotal:

$8.99
Shipping:

Total
$29.96
Title: Re: Poulan 415
Post by: Cut4fun . on January 04, 2019, 10:21:27 am
2 was put on back order through the dealer I ordered.  Other 1 I think they said not going to carry anymore through husky. 

415 65cc old style - 425 65cc updated and air injection.
445 70.7cc updated and air injection
475 76.5cc old style
505 82.5cc updated and air injection

415 425 445 have quad port cylinders
475 505 dual trans ports.
Title: Re: Poulan 415
Post by: Cut4fun . on May 29, 2019, 10:44:41 am
PP415 Pretty nice looking and was told just homeowner use for sale on chainsaw repair group FB.  If anyone is interested. Will save pics in a bit.

It is one of those BIN prices IMO. Oh clutch cover is busted up in middle section.  About 2.5hrs south of me.


pics


Just going to save this partner 660 pic here too. 
Title: Re: Poulan 415
Post by: Cut4fun . on December 08, 2019, 11:55:04 am
Just wanted to make sure the PP415 was 100% ready to go to new owner in Jan. If he dont change his mind. I just didnt want to ship during the month of Dec with USPS being it is going to the great white north PNW crossing the border. 24" full comp 3/8.

The one that has the updated AV, PP505 tank and air filter set up.

Also ran the G660 some and did some noodling.

Title: Re: Poulan 415
Post by: Cut4fun . on February 12, 2020, 08:43:22 pm
Visited CCC Racing shop today in Ohio. David Smith was a super host.

Many thanks for letting me run the bad to the bone poulan 4ci. Gave me a adrenaline rush I haven't felt since I quit racing saws. Shared some good stories and laughs.

I think Dave is a closet poulan lover myself ;) . He even had a box of NOS parts he has been saving for me to pick up. Recognize some of them off the top, but will need to research others.

Dave even had a CCC Racing hat for me. Also gave him the Racesaws hat I had stored back from 2008 era.

I also think Super Dave as a addiction to different type chains. Pretty wild all the different ones he has around the shop.

You might know this poulan when seen and the builder here too. Job well done. Hats off to ya, Dont know if you want your name mentioned so didnt say.


Title: Re: Poulan 415
Post by: SquareFile on February 13, 2020, 02:22:41 pm
https://youtu.be/Kcen4UY5Duk
Title: Re: Poulan 415
Post by: Cut4fun . on February 13, 2020, 05:03:37 pm
I ask Dave. I was like you got a cull chain on it for gtg type stuff right. He was like nope pretty decent chain. That worried me. So told him I'll just do down cuts.
Title: Re: Poulan 415
Post by: 3000 FPS on February 13, 2020, 09:03:51 pm
Pretty cool stuff.   Like the video. 
Title: Re: Poulan 415 vent master
Post by: Cut4fun on February 27, 2020, 08:52:53 am
That one full wrap 415 I had bought had come from a fire department.   It had a cut back half and the large spike trimmed down. Never thought anything about it till I seen this poulan 415 ventmaster. 

It dont have the cut clutch cover but same trimmed down bumper on the full wrap. Same d-ring handle on both.   Shows the b+c set up used and stickers.



Title: Re: Poulan 415 ventmaster
Post by: Cut4fun on February 27, 2020, 08:59:00 am
See if I can find that FW 415 pics.  Had same everything but stickers and b+c. 

Same d handle, front bumper deal etc. 



(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=56.0;attach=25500;image)
(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=56.0;attach=25502;image)
(http://chainsawrepair.createaforum.com/index.php?action=dlattach;topic=56.0;attach=25504;image)
Title: Re: Poulan 415
Post by: 3000 FPS on February 27, 2020, 01:04:40 pm
That 415 ventmaster sure is nice looking. 
Title: Re: Poulan 415
Post by: Cut4fun . on March 18, 2020, 03:53:19 pm
Need a collectors point of view. The clean one is when I learned what I had.

I'm thinking about getting out of this series of saws finally. Been selling off some of the whole saws and parts for a bit now.
My question is on this PP415 ventmaster I have. Should I put it back the way it should be at a collector stand point? I have it in parts all over the shelves right now.
Mine didnt have the stickers on it when it came to me. But was from a FD. I never even knew there was a poulan ventmaster till the one I seen on ebay. Clean one in pics.
Title: Re: Poulan 415
Post by: 3000 FPS on March 18, 2020, 11:29:05 pm
I would put in back just the way you found it.   
Title: Re: Poulan 415
Post by: Cut4fun . on March 19, 2020, 09:15:54 am
I would put in back just the way you found it.   

Collectors seem to think it isnt worth any extra as a fire department saw.  Unless a FD type collector was looking for such. Have been told they look for older FD stuff not the modern age.   

So am not going to worry about it.   Was just trying to make sure is all.
Title: Re: Poulan 415
Post by: Cut4fun on May 28, 2020, 08:39:48 am
I set my first poulan 415 I had bought from original owner today back up with original bar it came with when he bought it at TSC. I had bought it in a box after loosing fight with tree long ago.

Just so folks could see how they were sold at one time in the FB group. The small dawg is the dawg I run for 16" bar. Forgot to put the medium dawg on.
Title: Re: Poulan 415
Post by: Cut4fun on May 28, 2020, 08:40:53 am
Got 3 of them ready to go today. 65cc 71cc 83cc

PP415 PP445 PP505

Title: Re: Poulan 415
Post by: 3000 FPS on May 28, 2020, 09:41:14 pm
Now that is a good trio to draw to.