Craftsman S1600 Chainsaw Manual

The Craftsman S1600 is a powerful 16-inch gas-powered chainsaw designed for homeowners and DIY enthusiasts. It features a 42cc 2-stroke engine, automatic oiling system, inertia-activated chain brake, anti-vibration handles, and a tool-free chain tensioning system. This manual covers safety instructions, assembly, operation, maintenance, troubleshooting, and storage procedures to ensure safe and efficient use.

1. Safety Instructions 2. Parts Identification 3. Assembly & Setup 4. Specifications 5. Operation Guide 6. Chain & Bar Maintenance 7. Engine Maintenance 8. Storage Guidelines 9. Troubleshooting 10. Warranty Information

Safety Instructions

Always wear protective gear: safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots. Keep bystanders at least 15 feet away. Never operate when tired or under the influence.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; use low-kick chain; avoid tip contact.
Chain Contact	Engage chain brake when not cutting; keep hands away from moving chain.
Fuel Handling	Refuel outdoors with engine off; use approved fuel mix (50:1).
Electrical Hazards	Do not operate near power lines or in wet conditions.
Falling Branches	Be aware of overhead hazards; clear work area.

Parts Identification

Key components of the Craftsman S1600 chainsaw.

Front Handle: With throttle trigger and throttle lockout.
Rear Handle: With on/off switch and choke control.
Chain Brake Lever: Inertia-activated safety brake.
Guide Bar: 16-inch Oregon-style bar.
Chain: Low-kickback safety chain.
Chain Tensioner: Tool-free adjustment wheel.
Oil Tank Cap: For chain lubrication oil.
Fuel Tank Cap: For gasoline/oil mixture.
Air Filter Cover: Removable for filter access.
Muffler: Spark-arresting muffler.

WARNING! Familiarize yourself with all controls before starting the engine.

Assembly & Setup

Unpack all parts. Assembly requires attaching guide bar and chain, filling fluids, and performing pre-operation checks.

Attach guide bar: Loosen bar nuts, position bar over studs, align adjustment pin.
Install chain: Place chain over bar sprocket, ensure cutting teeth face forward.
Tension chain: Use tensioning wheel until chain snaps back when pulled.
Tighten bar nuts: Secure bar nuts after proper tension is set.
Fill fuel: Use fresh 89+ octane gasoline mixed with 2-cycle oil (50:1 ratio).
Fill bar oil: Use SAE 30 bar and chain oil; check for leaks.
Check controls: Verify throttle, brake, and switch operation.

CAUTION! Do not start engine until assembly is complete and all fasteners are tight.

Specifications

Engine: 42cc 2-stroke, air-cooled.
Bar Length: 16 inches.
Chain Pitch: 3/8" low-profile.
Chain Gauge: 0.050".
Fuel Capacity: 10.1 fl oz (300 ml).
Oil Capacity: 6.8 fl oz (200 ml).
Weight: 10.8 lbs (4.9 kg) without fuel.
Sound Level: 106 dB(A) at operator's ear.
Vibration Level: 4.5 m/s² front/rear handle.
Warranty: 2-year limited warranty.

Operation Guide

Starting procedure and basic cutting techniques.

Starting Cold Engine:

Place saw on flat ground, clear of debris.
Engage chain brake by pulling lever forward.
Move ON/OFF switch to ON position.
Pull choke knob fully out.
Press throttle lockout and squeeze throttle trigger once.
Pull starter rope briskly until engine fires (1-3 pulls).
Push choke knob in halfway.
Pull starter rope until engine starts.
Allow to warm up for 30 seconds before disengaging brake.

Basic Cutting: Use lower part of bar for cutting; let chain do the work; avoid forcing. For felling, use proper notch and backcut techniques.

Chain & Bar Maintenance

Regular maintenance ensures optimal cutting performance and safety.

Chain Sharpening: Use round file (5/32") at 30° angle; file each tooth equally.
Depth Gauge Setting: File depth gauges to 0.025" below cutting edge.
Bar Maintenance: Clean bar groove weekly; flip bar monthly for even wear.
Chain Tension: Check tension frequently; adjust when chain sags from bar.
Lubrication: Check oil flow before each use; refill with clean bar oil.

Tip: Always stop engine and wear gloves when handling chain.

Engine Maintenance

Air filter, spark plug, and fuel system maintenance schedule.

Component	Maintenance Interval	Procedure
Air Filter	Every 10 hours	Remove cover; clean with soapy water; dry completely.
Spark Plug	Every 25 hours	Clean electrode; gap to 0.025"; replace if worn.
Fuel Filter	Every season	Replace in-tank fuel filter.
Muffler	Every 50 hours	Remove spark arrestor screen; clean carbon deposits.
Cylinder Fins	Monthly	Clean cooling fins with brush to prevent overheating.

WARNING! Allow engine to cool completely before performing maintenance.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

Drain fuel tank or add fuel stabilizer.
Run engine until carburetor is dry.
Remove chain; clean and soak in oil.
Clean entire saw; apply light oil to metal surfaces.
Store in dry, cool place away from children.

CAUTION! Never store with fuel in tank for more than 30 days without stabilizer.

Troubleshooting

Problem	Possible Cause	Solution
Engine won't start	No spark, flooded, old fuel	Check spark plug; wait if flooded; use fresh fuel mix.
Engine runs then dies	Clogged fuel filter, dirty air filter	Replace fuel filter; clean air filter.
Chain won't turn	Brake engaged, clutch worn	Disengage brake; inspect clutch drum and springs.
Chain throws oil	Overfilled oil tank	Drain excess oil; check oil pump setting.
Excessive vibration	Loose parts, unbalanced chain	Tighten all fasteners; sharpen chain evenly.
Poor cutting performance	Dull chain, improper tension	Sharpen chain; adjust tension.

Service: For repairs beyond basic maintenance, contact authorized Craftsman service center.

Warranty Information

Craftsman S1600 chainsaw is covered by a 2-year limited warranty against defects in materials and workmanship. Warranty does not cover normal wear, misuse, or improper maintenance. Keep original receipt as proof of purchase. For warranty claims, contact Craftsman Customer Service at 1-888-331-4569 or visit www.craftsman.com.