Craftsman S160 Chainsaw Manual

The Craftsman S160 is a powerful and reliable gas-powered chainsaw designed for homeowners and DIY enthusiasts. It features a 16-inch guide bar, a robust 2-cycle engine for demanding cutting tasks, automatic oiling system, anti-vibration handles, and a quick-stop chain brake for enhanced safety. Below are key sections covering safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: 16-inch guide bar and chain, 2-cycle gasoline engine, Automatic chain oiler, Chain brake, Anti-vibration system, Front hand guard, Throttle trigger lockout, Decompression valve (if equipped).

Safety Information

Read and understand all safety warnings before operation.

1. Personal Protective Equipment (PPE): Always wear safety glasses, hearing protection, gloves, chainsaw chaps/pants, and sturdy boots.
2. Clear Work Area: Ensure no bystanders, pets, or obstacles within 15 feet.
3. Kickback Awareness: Be aware of the kickback zone (upper quadrant of bar tip). Maintain firm grip with both hands.
4. Chain Brake Test: Test chain brake function before each use by engaging it with the front hand guard.
5. Fuel Safety: Refuel in well-ventilated area, away from ignition sources. Allow engine to cool.

WARNING! Chainsaws are dangerous tools. Failure to follow safety instructions can result in serious injury or death. Never operate while tired, under the influence, or in poor weather conditions.

Assembly & Setup

Unpack and inspect all parts. Assembly requires basic tools (screwdriver, wrench).

1. Attach Guide Bar & Chain: Loosen bar nuts. Place chain over sprocket, ensuring cutting teeth face forward on top of bar. Align bar with tensioning pin. Tighten nuts finger-tight.
2. Adjust Chain Tension: Use tensioning screw to raise bar until chain fits snugly against bar (should pull away about 1/8 inch from bar in middle). Tighten bar nuts securely.
3. Fill Oil Tank: Use high-quality bar and chain oil. Fill to marked level.
4. Mix Fuel: Use fresh unleaded gasoline (minimum 89 octane) mixed with 2-cycle engine oil at a 50:1 ratio (2.6 fl oz oil per 1 gallon gas). Shake well.
5. Initial Check: Ensure all fasteners are tight. Test chain brake and throttle lockout.

CAUTION! Chain must be properly tensioned. A loose chain can derail; an overtightened chain can damage the engine and bar.

Specifications

• Model: Craftsman S160.
• Engine Type: 2-cycle, single cylinder, air-cooled.
• Displacement: 40 cc.
• Power Output: 2.0 HP.
• Max Engine Speed: 13,500 RPM.
• Idle Speed: 2,800 - 3,200 RPM.
• Fuel/Oil Ratio: 50:1 (Gasoline to 2-cycle oil).
• Ignition System: Electronic (CDI).
• Starter: Recoil with decompression valve.
• Sound Power Level: 112 dB(A) (Wear hearing protection).
• Vibration Level: Front Handle: 4.5 m/s², Rear Handle: 5.5 m/s².

Controls and Components

Familiarize yourself with all controls before starting.

Main Components: Front Handle with Hand Guard/Chain Brake, Rear Handle with Throttle Trigger, Throttle Trigger Lockout, Choke Lever, Primer Bulb, Stop Switch, Decompression Valve Button, Chain Tensioning Screw, Bar Nuts, Fuel Cap, Oil Cap.

Operation: The throttle trigger lockout must be depressed before the throttle trigger can be squeezed. The chain brake is engaged by pushing the front hand guard forward. The stop switch stops the engine.

Fuel & Oil

Use only fresh, clean fuel and specified oils.

1. Fuel Mix: 50:1 ratio. Use gasoline with ≤10% ethanol (E10). For storage over 30 days, use fuel stabilizer.
2. Bar & Chain Oil: Use a quality oil designed for chainsaw use. Do not use waste or motor oil.
3. Filling: Clean area around caps. Fill tanks on a level surface. Wipe up any spills immediately.
4. Checking Oil Flow: Hold saw over light-colored surface and run at high idle. A fine line of oil should appear on the surface.

Tip: Mark fuel cans clearly. Never use fuel older than 60 days.

Starting & Operation

Follow cold start procedure for initial use or after prolonged storage.

1. Cold Start: Place saw on firm, level ground. Engage chain brake. Set stop switch to "I" (On). Pull choke lever out fully. Press primer bulb 5-6 times until fuel is visible. Pull starter rope sharply until engine 'pops'. Push choke lever in halfway. Pull starter rope again until engine starts. Allow to idle for 10-15 seconds, then squeeze throttle to disengage choke.
2. Warm Start: Do not use choke. Follow steps above, starting with stop switch "On".
3. Cutting Technique: Use full throttle when cutting. Let the saw do the work; do not force it. Be aware of pinch points, especially when cutting logs under tension.
4. Stopping: Release throttle, allow engine to idle, then press stop switch to "O" (Off).

WARNING! Always engage the chain brake when starting, carrying, or when not actively cutting. Keep both hands on the handles at all times during operation.

Chain Maintenance

Regular maintenance ensures optimal performance and safety.

1. Sharpening: Use a round file matching chain pitch (.325"). File each cutter at the manufacturer's specified angle (typically 30°). Maintain equal file strokes per cutter. File depth gauges with a flat file and gauge.
2. Tensioning: Check tension frequently, especially when chain is new. Chain should be snug but pull freely by hand. Re-tension when engine is cool.
3. Cleaning: Remove debris from guide bar groove, oil holes, and sprocket cover after each use.
4. Rotation: Flip the guide bar periodically to promote even wear.

CAUTION! Wear heavy gloves when handling the chain. A sharp chain cuts faster, requires less force, and is safer than a dull one.

Storage & Care

Prepare saw for storage if not used for more than 30 days.

1. Drain all fuel from tank and run engine until it stops to clear carburetor.
2. Remove chain, clean it and the bar with solvent, dry, and coat with oil.
3. Clean entire saw, removing sawdust and dirt from cooling fins and air filter.
4. Store in a dry, secure place, out of reach of children.

CAUTION! Never store with fuel in the tank for extended periods. Old fuel can gum up the carburetor.

Warranty Information

The Craftsman S160 is backed by a limited warranty. Proof of purchase is required. This warranty covers defects in materials and workmanship for a specified period from the date of purchase. It does not cover damage from misuse, lack of maintenance, normal wear, or use of non-genuine parts. For warranty service, contact Craftsman Customer Support at 1-888-331-4569 or visit www.craftsman.com. Keep your receipt.

Troubleshooting

Service: For repairs beyond basic maintenance, consult an authorized Craftsman service center. Use only genuine Craftsman replacement parts.

Support: 1-888-331-4569; www.craftsman.com