Chainsaw Repair

Husqvarna - Stihl - Poulan - Jonsered - Dolmar chainsaws and more => Poulan => Topic started by: HolmenTree on May 30, 2015, 11:59:58 am

Title: Poulan 5200 - 8500
Post by: HolmenTree on May 30, 2015, 11:59:58 am
I always admired the 85cc 5200, 5400 and 8500 Poulans from the past.  My brother raced a couple with pipes back in the day. Also 7 time Hayward world champ Ron Hartill and his son Dale raced really fast ones.
 Back in 1975 when the 5200 was introduced I can't think of another saw at the time that could beat it's power to weight ratio and ergonomics.

Here's the best video I could find of a 5200, as this guy could handle it pretty good and also not screw up the chain with bad hand filing.
Appears the slow idle down time after the cut may require an upgrade to the reed valve or maybe crank seals, ran strong in that big hardwood though.
 
Very nice video.....anyone know who he is? And also what upgrades were from the 5200 of 1975 to the 8500 of 1984?

https://youtu.be/WAfUhon63eg
Title: Re: Poulan 5200 - 8500
Post by: 3000 FPS on May 30, 2015, 12:43:28 pm
I like the 5200 also but I also have some Poulan 505.    For power to weight I think will use the 505's I have.   Both saws I think are easy to work on and maintain.   I have never compared the two but your video of the 5200 sure does look like it does very well in wood.   Thanks for the vid.
Title: Re: Poulan 5200 - 8500
Post by: Eccentric on May 30, 2015, 01:10:01 pm
My Craftsman 5.2/30 (Red Sears badged 5200) and Poulan 8500 are two of my favorite saws. 

I agree that his saw sounds like it may have a leaking crank seal.  Probably the FW side, as when the PTO side seal leaks on these they usually smoke a bit as that seal has the wet side of the auto oiler pump over it.  My 4900 ran great when I first got it, but smoked and was a bit slow to return to idle.  Both symptoms went away when I replaced the crank seals.

530019075 is the Poulan # for the seals.

SKF 6904 and National/Timken 471466 are numbers you can use to get seals from bearing houses and auto parts outlets.
Title: Re: Poulan 5200 - 8500
Post by: Cut4fun . on May 30, 2015, 01:48:25 pm
I dont know squat about them but have ran some.

http://chainsawrepair.createaforum.com/poulan/poulan-8500/

http://chainsawrepair.createaforum.com/poulan/poulan-5400-5200-5200/

http://chainsawrepair.createaforum.com/poulan/poulan-8500-2075/msg21727/#msg21727

http://chainsawrepair.createaforum.com/poulan/poulan-8500-case-repair/



http://chainsawrepair.createaforum.com/poulan/poulan-8510/

Title: Re: Poulan 5200 - 8500
Post by: Cut4fun . on May 30, 2015, 01:58:06 pm

Very nice video.....anyone know who he is?

He is a member here and from Ohio.   Just be careful dealing with. Have heard GOOD and BAD.
Title: Re: Poulan 5200 - 8500
Post by: HolmenTree on May 31, 2015, 08:07:20 pm
Thanks guys. Does anyone know what upgrades were done between the 5200 ,5400, 8500?
Title: Re: Poulan 5200 - 8500
Post by: fossil on May 31, 2015, 09:04:48 pm
I couldn't list them all but the motors stayed pretty much the same. Bar studs were changed from 5/16 to 3/8, the 5400's added a hand guard to the rear handle.
The starters were upgraded for durability and 10-24 fasteners for the starter housing to case were changed to 1/4 - 20. At some point early on a rib was added to the front of the case for durability and the top cover fastening was changed from a captive nut with locating pins to three screws. That was likely for a cost savings. The starter housing was changed, I believe by adding a stud to anchor the recoil spring.
The 8500 had a different air filter system.

The power stayed the same as I guess that was very difficult to improve on.
I couldn't agree more as to how powerful and innovative these saws were when they were introduced.
Title: Re: Poulan 5200 - 8500
Post by: HolmenTree on May 31, 2015, 10:17:19 pm
Thanks Tim. Good information.
 I'm hoping my older brother will part with some of his 5400/8500 Poulans. I believe his newest 8500 has an actual working chain brake on it as that was the law for saws to be sold in Canada.
One of his saws [not sure if it's a 5400 or 8500] has a tune pipe and WB carb on it, thing was pretty hot back in the day in "10x"10".
I will definitely post pics when I can. :)
Title: Re: Poulan 5200 - 8500
Post by: Eccentric on June 01, 2015, 05:29:39 am
Looking forward to pics.  The 6900/7700/8500 has a plastic top cover with separate af cover to go with the different af that Tim mentioned. 

The 4400/4900/5400 and later saws have a longer tank/rear handle casting.  More fuel capacity (and distance between the handlebar and rear handle.............and more weight). 

The plug lead is different on the coil of the 6900/7700/8500 saws. 

The 6900/7700/8500 saw cylinders have a different fin profile than the 1st and 2nd gen saw cylinders.  The bulkhead behind the jug is different to match. 

The 6900/7700/8500 saws have a larger crank PTO snout, with a larger clutch bearing and race and a different clutch drum and hub.

Tim covered the remaining upgrades.  The 3/8 bar studs were phased in during the 4400/4900/5400 production.  There were 2nd gen saws with both stud sizes.  My 4900 had 5/16" studs.
Title: Re: Poulan 5200 - 8500
Post by: HolmenTree on June 01, 2015, 08:58:20 am
Thanks Aaron,
Looks like the newer generation was beefed up adding more weight but the newest series got a smaller fuel tank to help get the weight back down again.
That's  how most pro saw models were developed,  like my '86 Stihl 064 that was only 14.1 lbs as it's  manual specs but by a few years later the 064s were well over 15 lbs.
Hard rain out today so may have a little time to search for Poulan pics.
Title: Re: Poulan 5200 - 8500
Post by: fossil on June 01, 2015, 12:03:16 pm
I have a NOS chain brake for the 4200 - 5200 saws that was a dealer add on if the customer wanted it. It may have been used to sell any old saw stock whent he chain brake reg came in. I would really love to know when that became mandatory in Canada. I can't find any info on that. I know a lot if not all of the later 3400 - 4000 series sold here had brakes. I'm guessing mid to late '80's.
Title: Re: Poulan 5200 - 8500
Post by: HolmenTree on June 01, 2015, 02:23:12 pm
1981 was the year Canadian  Safety  Standards  (CSA) required chain brakes on all gas powered chain saws.
Title: Re: Poulan 5200 - 8500
Post by: Eccentric on June 01, 2015, 03:12:25 pm
I have a NOS chain brake for the 4200 - 5200 saws that was a dealer add on if the customer wanted it. It may have been used to sell any old saw stock whent he chain brake reg came in. I would really love to know when that became mandatory in Canada. I can't find any info on that. I know a lot if not all of the later 3400 - 4000 series sold here had brakes. I'm guessing mid to late '80's.

I need to buy one of those CB kits from Bryce for my 8500 so I can use it in the park where I do volunteer cutting.  They require CB's for their insurance.  I may have used some non-CB saws (SXL-925, S-250, 4900) there a few times though. 8)
Title: Re: Poulan 5200 - 8500
Post by: 660magnum on June 01, 2015, 03:20:32 pm
I have a Poulan 3500 that never had a chain brake and I don't give it a thought?

My older son always sets the chain brake on my saws. I don't usually mess with them.

My other saws have inertia type chain brakes. Never had one trip.