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I have a 1980 poulan 4200, starts and runs, but no power and 'chugging' when throttled. replaced fuel line, rebuilt carb, no exhaust obstructions, compression is okay ~130psi what's next? Dan

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Air cleaner may be plugged. This sounds like too much fuel going into the engine. When you serviced the carburetor, did you replace the diaphragm in the lower chamber and check the needle valve that the diaphragm operates? Did you clean or replace the fuel filter in the tank? If everything has been taken care of, turn both jet screws CW to stops (lightly), then back each out CCW 1-1/2 turns. Start the engine and allow to warm up. Pull the throttle full on, and turn H jet needle CW until the engine starts to speed up. Proper final adjustment is when the engine 4-strokes, but immediately 2-strokes when cutting. Release the throttle and adjust L jet needle CW so that the engine idles fairly well, but will allow the engine to 'follow the throttle'. Adjust idle speed screw so that the engine continues to run, but the chain does not try to turn. Hope this helps!

Posted on Nov 04, 2010

  • namesmattern Nov 05, 2010

    I removed the air cleaner for testing. Fuel filter and line are both new. The diaphragm, needle valve, and rocker were replaced with the carb rebuild. the kit did not include new jet screws, which suprised me. I started by backing out 1 turn and going each way from there. It still seems to chugg at any setting. Do you think this might be a spark issue? maybe a dying ignition module or something?
    Thanks for your help. Dan

  • drallim Nov 06, 2010

    Did you wash out the fuel tank which might have had a residue of old oil in it? Check the ignition module gap clearance by removing the left side cover to expose the flywheel and module. Turn the flywheel magnets under the module poles, insert a thin business card in the gaps, loosen the module screws and allow the module to contact the magnets. Tighten the screws, and recheck for spark which should be blue and snappy. Make sure the plug is gapped at 0.020" and the insulator inside is a tan color. If black, then too much fuel (or excess oil) is going into the engine. When replacing the diaphragm in the carburetor, the gasket should go between the diaphragm and the cover. Go to: for a 12 page article on Walbro carburetor theory and troubleshooting. Hope we are getting closer to the problem!



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