How to Replace the Ignition Wire Harness on a Poulan Chainsaw (Model P3314)

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The wiring harness connects the ignition coil to the switch. It is made up of two wires: One carries power from the coil to the switch. The other has a switch contact on one side, and attaches to the engine ground on the other.

A piece of heat shielding protects the wires from damage (caused by the extremely hot engine). The wires can be damaged, causing a loss of continuity in the kill circuit, or causing an undesirable grounding issue, which will shut off the saw.

Often, a faulty wire can be diagnosed visually. Look for a broken wire, melted insulation, or loose connections. If you don't see anything that looks out of the ordinary, you can use a multimeter (and test for continuity) to find the offending wire or connection.

This article provides step-by-step instructions for replacing the ignition wire harness on a Poulan chainsaw.

Let's get started.   REMOVING THE IGNITION WIRING HARNESS [top] 1. Remove top cover.

Remove the (3) screws securing the top cover to the saw.

Lift the top cover away from the saw.

  2. Remove the starter assembly.

Remove the (4) screws securing the starter assembly to the (side) of the saw.

Remove the starter assembly from the saw.

  3. Disconnect the ignition coil.

Remove the spark plug boot from the spark plug.

Use long-nosed pliers to disconnect the wire connector from the ignition coil.

  4. Remove the harness clip.

Use long-nosed pliers to pull the metal harness clip away from the engine.

  5. Remove the ignition coil.

Remove the front screw securing the ignition coil to the engine. (Note that one of this screw also secures the grounding eyelet to the saw).

Remove the rear screw securing the ignition coil to the engine.

Lift the ignition coil away from the saw.

  6. Remove the air filter cover.

Remove the air filter cover from the air filter housing.

  7. Remove the ignition wire harness.

Use long-nosed pliers to disconnect the ignition wire from the top of the ignition switch spring.

Use a screwdriver to pry the ignition ground wire connector out of the ignition switch lever.

Remove the ignition wire harness from the saw.

  INSTALLING THE NEW IGNITION WIRING HARNESS [top] 8. Connect the ignition switch wires.

Switch the ignition lever to the “on” position.

Slide the ground wire contact into the ignition switch lever.

Tuck the ground wire into the holders on the switch lever.

Connect the ignition wire to the top of the ignition switch spring.

  9. Install the ignition coil.

Tuck the wires of the new harness into the recess beneath the brake handle assembly.

Partially install the ignition coil onto the engine.

Tuck the spark plug wire (connected to the ignition coil) into the recess beneath the brake handle assembly (on top of the harness wires).

Thread the front mounting screw through the eyelet on the new ground wire.

Thread the front screw (containing the ground wire) through the ignition coil and into the engine; do not yet tighten.

Thread the rear screw through the ignition coil and into the engine; do not yet tighten.

  10. Set the ignition air gap.

An ignition gapping gauge is recommended to accurately complete this step. However, if you do not have an ignition gapping gauge (measuring #.014 or .35mm), it is usually acceptable to use one thick business card, or two thin business cards as substitutes.

Insert the ignition gapping gauge between the ignition coil and the flywheel.

There are two magnets on the outside of the flywheel. Rotate the flywheel until these magnets align with the contacts on the ignition coil.

Adjust the position of the ignition coil until the contacts engage the magnets of the flywheel.

Tighten the (2) screws to secure the ignition coil.

Connect the ignition wire (plastic connector) to the ignition coil.

Remove the gapping gauge.

  11. Secure the wires.

Grasp the wires in the ignition harness (on the flywheel-side of the ignition coil), and gently pull the wires toward the ignition switch to remove any slack from the (coil-side) wiring harness.

Gently pull the spark plug wire toward the ignition switch to remove any slack from the (coil-side) spark plug wire.

Center the segment of heat shielding (on the wire harness) over the engine cylinder.

Tuck the wire harness into the recess on the engine.

Secure the wire harness and the spark plug wire with the metal clip.

  REASSEMBLING THE UNIT [top] 12. Reinstall the starter assembly.

Install the starter assembly to the engine.

Pull the starter rope slowly until the flywheel engages the starter assembly.

Secure the starter assembly to the engine with the (4) screws.

  13. Reinstall the spark plug boot.

Connect the spark plug boot to the spark plug.

  14. Reinstall the air filter cover.

Install the air filter cover onto the air filter housing (over the air filter).

  15. Reinstall the top cover.

Install the top cover onto the saw.

Secure the top cover with the (3) screws.

Do-it-yourself repairs like these are easier than you might think: From lawn machines to cordless drills, kitchen mixers to outdoor grills. Our "how-to" articles walk you through each repair from start to finish.

So, doing-it-yourself means never having to do it alone.

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