What is the replacement size for a poulan pp5020av pull cord?

.025" plug gap

ok this depends on which side you pulled the side with the bar there is a chain tension adjustment it has to be in place for that side to sit down then on the pull cord side you have to pull the cord a little to get it to sit down in place hope this helps out

The length of the Starter pull cord is 40"
It can be purchased at www.ereplacement parts.com

I have no affiliation with this site or company. They simply have great prices and also list exploded views of this saw and others.

http://www.ereplacementparts.com/poulan-pp5020av-stroke-gas-chainsaw-parts-c-16962_17147_162366.html

www.ereplacementparts.com lists the part as Kit Rope 40" (Type 4.5)
Part Number: 530069919 Priced at $2.84 and if you need a new handle, it's only $2.73

The link is below.
http://www.ereplacementparts.com/poulan-pp5020av-stroke-gas-chainsaw-parts-c-16962_17147_162366.html

When you remove the recoil shoot a little oil on the moving parts. sometimes they get dry or even rusty and binds.

More details on the brake would assist.

Check and see if you have pulled a hose or have punctured the tank. See if you can see where it leaks from. Try pulling your starter cord slowly and see if you can see any leak. Maybe have some one pull it while you watch for the leak.

http://www.ehow.com/info_8137879_size-file-do-need-chainsaw.html

You need to wind the spring back in a coil at a time, it is not easy if you have never done one, order a new spring, this will come pre wound in a cassette and is an easy fit.

by undo'ing the nut on the side over top of bar , then the entire case cover should lift off that side and then the clutch is visible , slacking up on chain tension screw till the chain can round the clutch and then entire bar and chain should just fall away