Poulan 8500 restoration
- Thread starter ctcown
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Thats not correct. A 5200/5400 cylinder will not fit a 8500.
The other saw you painted green, it has the wrong recoil cover for a extended tank saw. The extended tank saws used 1/4" screws to hold the recoil on and the cases were reinforced for the larger screws as well. If your using a 4200/5200 case it will have 10-24 screw holes and use the cover you posted.
Also just so you know, the muffler you have on the 8500 is not correct for it, the 8500 muffler had a 90 degree outlet on it.
Correct Mark the case on that saw is off of a 4200-5200 and does not have the 1/4 screws or the later reinforced starter cover with the pin. However it will still make a functional saw I'm not necessarily into originality.
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Thats fine, was just pointing it out in case you didn't notice and found you had the wrong fasteners.
You should have let me know on the case gasket, I could have sent you the gasket scans to make it easy to cut them out.
You should have let me know on the case gasket, I could have sent you the gasket scans to make it easy to cut them out.
Also the crankcases for a 4400-5400 are different than the 6900-8500. There is additional webbing in the rear near the tank and handle where the top cover screws are and some slight webbing on the bottom of the case compared to the 4400-5400 however the earlier cases work perfectly. Also the part numbers are different. I can't find any difference in the 5200-5400 cylinders vs the 8500 other than a part number change.
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Excellent work and beautiful saws!!!
Lol I'm a moron with computers I have the scans from another site you did Mark but when I print them out they come out oversized for some reason so I figured I'd try inking the case and printing my own it works pretty good. However I'd like to know what I keep doing wrong with the pdf file that would be easier.
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Build them the way you want them 
. Its you that will be using and enjoying them.
Dare to be different I say WTG.
. Its you that will be using and enjoying them. Dare to be different I say WTG.
echoshawn
....Beer is good.....
Did you check partstree as well for parts?
All that is correct, Poulan kept beefing the cases up as they went. The first the big deal for the 4400,4900 and 5400 was the webbing behind the coil to keep it from breaking, along with the beefed up recoil cover bosses to go with the new style HD recoil cover.
There is a reason for the part number change on the 8500 cylinders. I too thought they were the same till I tried to bolt a 5200 cylinder on it. Look closely at the fins on the lower rear of the cylinder, the 8500 cylinder has them shaved down some to clear the new style intake etc.
Trust me, you cannot just bolt a 5200 cylinder on the 8500, at least not with the intake on it.
