Replacing A Chainsaw Fuel Line: Step-By-Step Guide

Changing the fuel line on a chainsaw is a dangerous and messy task, so it's important to wear safety equipment, including gloves, a jacket, and chaps. Before you begin, ensure you have the right tools for the job, including a manufacturer-recommended fuel line, pliers, and a screwdriver. Place your chainsaw on a flat surface, drain the old fuel, and remove the cylinder cover and air filter. You will then need to remove the air filter housing, fuel filter, fuel and vent line, carburetor, and fuel line. Finally, install the new fuel line and close your chainsaw.

How to change a fuel line on a chainsaw

Prepare your chainsaw

To prepare your chainsaw for a fuel line change, you should first ensure that the chainsaw is switched off and cold. Place the chainsaw on a flat surface, such as a table at waist height, to avoid having to bend over while working. It is important to wear protective gear, including work gloves, a jacket, and chaps, as repairing a chainsaw can be dangerous and messy.

Next, drain the old fuel from the chainsaw by opening the fuel cap and emptying the fuel tank into an approved storage container. Keep this container nearby, as you can use the old fuel to clean the inside of the components you will be removing.

Now, you can begin to remove the components. Using a screwdriver, remove the cylinder shield by taking out the nuts that hold it in place. Most Craftsman chainsaw models have 3-4 nuts on the shield. Once the nuts are removed, you can lift off the shield and take out the air filter. Check if the air filter can be cleaned and reused, or if it needs to be replaced. If your chainsaw model has a spark plug, disconnect and remove it.

At this point, you should also remove the air filter housing. There are usually two bolts holding the air filter housing in place. Carefully inspect the throttle linkage attached to the backside of the air filter housing, as you will need to reattach it in the same way during reassembly. Taking a picture with your phone can be helpful for reference later.

Remove the fuel

To remove the fuel from your chainsaw, you must first place it on a flat surface, preferably a waist-high table, to avoid having to bend your back while working. Be sure to wear work gloves for protection.

Next, grab an old container and empty the old fuel and other components from the gas tank into it. Keep this container close by, as you can use the old fuel to remove accumulated dust and debris from the inside of the components that you will be removing in the following steps.

Now, disconnect the spark plug wire and remove the air filter. Pull the cover off the air filter housing and remove the filter. You may need to replace the fuel filter if it is dirty and no longer functional.

Finally, use a steel coat hanger to remove the fuel filter from the chainsaw's fuel tank. Straighten out one end and slide it inside the fuel tank to retrieve the fuel filter. Then, detach the fuel line from the filter.

Remove the cylinder cover and air filter

To remove the cylinder cover and air filter, you will need a screwdriver. First, use the screwdriver to remove all the nuts on the cylinder shield. Craftsman chainsaws typically have three or four nuts on the shield. Once these are off, you can lift the cover off and remove the air filter. Check if the air filter can be replaced after washing it with fuel. If it is too dirty, you will need to replace it. You should also disconnect the spark plug.

Remove the carburetor

To remove the carburetor, you will first need to remove the cylinder cover and air filter. Using an appropriately-sized screwdriver, remove all the nuts on the cylinder shield. Craftsman chainsaws typically have 3-4 nuts on the shield. Once the nuts are off, you can remove the cover and take out the air filter.

Next, disconnect the spark plug and remove the air filter housing. There will be two bolts holding the air filter housing in place. Pull out the housing and keep it to one side, being careful not to lose the nuts and other small parts. The throttle linkage will be attached to the backside of the air filter housing, so be careful not to dislodge it. Taking a photo with your phone can be helpful here to remind you how to reassemble it later.

Now you can remove the carburetor. Using a 7/16-inch socket driver, remove the two mounting nuts that secure the carburetor to the engine. Pull the carburetor from the engine block, sliding it along the mounting studs. Be careful not to bend the throttle linkage or damage the gas lines.

Install the new fuel line

Now that you have successfully removed the old fuel line, it is time to install the new one.

Firstly, you should splice one end of the new fuel line with scissors. This will help you feed the line into the hole for the fuel line. Be careful while doing this as it can be slightly technical. Once you have fed the line into the hole, you will be able to get a hold of it from the other side, making it easier to pull it through.

Next, compare the new fuel line with the old one to get an idea of how much pipe you need to insert into the carburetor. Ensure that you have enough length of the line on the other side to attach the fuel filter. Once you have attached the pipe to the carburetor and the primer bulb line, you can attach the fuel line to the fuel filter before putting it inside the fuel tank.

Now, you can close the chainsaw. Place the carburetor back in its place, ensuring that it fits perfectly on the studs. Then, attach the throttle linkage on the backside of the air filter housing. The photos you took earlier of the throttle linkage will be useful here. Put the air filter housing back in its place and tighten the bolts.

If everything is placed correctly, you will not need to force anything when fitting the housing. Place the air filter in its place before connecting the spark plug. Finally, screw down the cylinder shield, ensuring that you have removed any oil, dust, or grease on the inside of the shield and air filter housing.

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