
If your chainsaw is not starting despite being filled with gas, the fuel line may be clogged or cracked. Chainsaw fuel lines are important as they transport fuel from the tank to the carburettor. They can become brittle and crack over time, and sometimes even disintegrate. Replacing them is not difficult and can be done without hiring a professional. However, it is a dangerous and messy task, so safety equipment such as gloves, a jacket and chaps should be worn.
Chainsaw Fuel Line Replacement Guide
| Characteristics | Values |
|---|---|
| Tools | Fuel line kit, hemostat pliers, Allen wrench, needle-nose pliers, scissors, utility knife, work gloves |
| Preparation | Wear gloves and work in a well-ventilated area. Drain fuel tank into approved storage container. |
| Step 1 | Remove fuel cap and use hemostats to remove the compression fitting and fuel line from the tank. |
| Step 2 | Cut old fuel line from plastic fitting. |
| Step 3 | Measure new fuel line to match the length of the old one. Cut at an angle to ease insertion into the tank. |
| Step 4 | Thread the new line into the tank. Push the large line about 1 inch in and the small line far enough to be grabbed with pliers. |
| Step 5 | Pull the small line out, cut the end square, and install the fuel filter. |
| Step 6 | Pull the line back so the filter rests at the bottom of the tank. |
| Step 7 | Trim the lines and connect them to the carburetor. |
| Step 8 | Reinstall the cylinder shield, air filter, spark plug wire, and refill the tank. |
| Notes | The fuel line kit may include a tool to help thread the line. You can also use boiling water to soften the line. |
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What You'll Learn

Clearing clogs and checking for cracks or crimps
If your chainsaw won't start, it could be due to clogged, crimped, or cracked fuel lines. To identify a clogged fuel line, carefully inspect the chainsaw, checking the fuel filter and examining the fuel line. Use a flashlight to get a closer look at the fuel line and other components of the chainsaw's fuel system. Pay attention to any areas where the fuel line may be bent or kinked, as this can obstruct the flow of gas.
To fix a clogged fuel line, first, locate the fuel line on your specific model. Once you've found it, disconnect the line from the carburetor and fuel tank. Then, use compressed air or a thin wire to carefully remove any debris or blockages from the line. Be sure to thoroughly clean both ends of the fuel line before reattaching it. If the line is damaged or cracked, it may need to be replaced with a manufacturer-approved chainsaw part.
To prevent clogs, it is important to use fresh and high-quality fuel for your chainsaw and avoid using old or contaminated fuel. Follow the manufacturer's recommendations for the fuel-to-oil ratio to prevent the formation of deposits that can clog the fuel line. Clean or replace the fuel filter regularly, and use a fuel line cleaner to dissolve any remaining blockages. Proper storage also plays a role in preventing clogs. Storing the chainsaw in a cool, dry place minimizes moisture accumulation, which can cause fuel contamination. It is also advisable to run the chainsaw dry before long-term storage to prevent fuel from sitting stagnant and breaking down within the lines.
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Removing the fuel lines from the gas tank
Before starting, ensure that your chainsaw is cold and placed on a flat surface, preferably a table that is waist height. This is a dangerous task, so wear safety equipment, including gloves, a jacket, and chaps. You should also take digital photos of the gas line connections for accurate reassembly.
Firstly, drain any excess fuel from the tank. Next, remove the mounting nuts and air filter housing. You can then pull the carburetor off the mounting studs. Now, pull the fuel lines off the carburetor and primer bulb, using needle-nose pliers. If you have a chainsaw with a remote purge bulb, you will need to remove the screws from the primer bulb to detach the fuel lines.
Now, carefully pull the fuel lines out of the gas tank, using needle-nose pliers. You can also try using hemostats or tying the tip of the line off with fishing line to weave it through. If you are still struggling to get the lines through the holes, you could try leaving them in boiling water to soften them or using a tool such as a thin piece of wire to thread them through.
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Cutting the new fuel lines
Firstly, it is important to ensure that you have the correct length of fuel line to work with. If you have purchased a genuine set of fuel lines, they may be cut to a specific length. In this case, it is recommended to leave them in boiling water for a while to make them more pliable and easier to work with. This can help prevent ripping or damage during the installation process.
Now, you can begin cutting the new fuel lines. It is suggested to cut the lines at a 45-degree angle, which will make threading them into the tank easier. This technique is commonly known as the "
When cutting the fuel lines, it is important to use sharp scissors or a similar tool to create a clean, sharp cut. Dull scissors may crush or deform the end of the tubing, making it more difficult to insert into the tank.
Once the fuel lines are cut to the correct length and angle, you can begin to thread them into the fuel tank. Push the large line about one inch into the tank. This will help secure the lines and provide a starting point for the next steps.
At this point, you can use needle-nose pliers or a similar tool to grab the small line through the mouth of the tank. Pull the small line out, cut its end square, and install the fuel filter. Finally, pull the line back into the tank so that the filter rests at the bottom.
By following these steps, you will be able to cut and install the new fuel lines for your chainsaw, ensuring a secure and functional fuel system.
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Reattaching the spark plug wire
To reattach the spark plug wire, first position the air filter in the housing and replace the cover. Then, simply reattach the spark plug wire. Finally, reinstall the cylinder shield on the chainsaw and refill the fuel tank.
If you are replacing the spark plug wire as part of a fuel line replacement, there are several steps you should follow. First, take digital photos of the throttle linkage on the carburetor and the gas line connections for accurate reassembly. Next, remove the mounting nuts, air filter housing, and carburetor. Then, pull the fuel lines off the carburetor, primer bulb, and out of the gas tank, using needle-nose pliers if necessary. Cut the new fuel lines at an angle to thread them into the tank, and push them into the tank. Finally, reassemble the carburetor, air filter housing, and mounting nuts, and reattach the spark plug wire.
If you are having trouble threading the new fuel lines through the holes in the fuel tank, there are a few techniques you can try. First, try leaving the lines in boiling water for a while to make them more pliable. You can also try cutting the end of the line to a sharp, long point to help guide it through the hole. If you have access to a set of hemostat pliers, these can be useful for grabbing onto the line and pulling it through. Additionally, you can thread a thin piece of wire through the hole, attach the fuel line to the wire, and pull it through.
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Using a fuel line kit
Prepare the Chainsaw:
- Wear protective gear, such as work gloves and safety goggles.
- Find a well-ventilated area to work in.
- Drain the fuel tank by removing the fuel cap and emptying the fuel into an approved storage container.
- Remove the screws securing the top cover to the saw and lift it away.
- Detach the air filter cover and remove the air filter from the housing.
- Disconnect the throttle linkage from the carburetor and slide the carburetor assembly away from the engine.
Remove the Old Fuel Lines:
- Use needle-nose pliers to carefully pull the old fuel lines out of the gas tank, carburetor, and primer bulb.
- If necessary, remove the screws from the primer bulb to detach the fuel lines.
Install the New Fuel Lines:
- Cut the new fuel lines from the kit at an angle to thread them into the tank.
- Push the large line about 1 inch into the tank.
- Push the small line into the tank and grab it through the mouth of the tank with needle-nose pliers.
- Pull the small line out of the tank, cut the end square, and install the fuel filter.
- Pull the line back into the tank so that the filter rests at the bottom.
- Trim the fuel lines as needed and connect them to the carburetor.
- Lubricate the fuel lines with a drop of oil to ease threading.
Reassemble the Chainsaw:
- Reinstall the carburetor, ensuring that the fuel lines are not crimped.
- Position the air filter in the housing and replace the cover.
- Reattach the spark plug wire.
- Reinstall the cylinder shield and refuel the tank.
Always refer to the instructions provided with your fuel line kit and ensure you are confident in performing the repair. If you encounter any difficulties or complications, seek assistance from a qualified technician.
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Frequently asked questions
If your chainsaw doesn't start even though it has plenty of gas, the engine might not be getting fuel because a fuel line is clogged or cracked. Issues in the chainsaw fuel lines can develop naturally over time, from storing your chainsaw with fuel in it to using old gas.
Firstly, ensure your chainsaw is cold and placed on a flat surface. Then, prepare your chainsaw, take out the old fuel, remove the cylinder cover and air filter, remove the air filter housing, take out the fuel filter, take out the fuel and vent line off, take out the carburetor, and take out the fuel line. Once you have removed all these things, install the new fuel line and close your chainsaw. Finally, test your chainsaw to see if everything is running smoothly.
This process is dangerous and messy, so wear safety equipment, including gloves, a jacket, and chaps. You can use a variety of tools to change the fuel lines, including pliers ?(needle-nose, hemostat, or tubing pliers with curved jaws), scissors, a utility knife, and a wire attached to a key ring. To avoid damaging the new rubber fuel lines, you can try greasing them or using a ballpoint pen spring.











































