Replacing Fuel Lines: Poulan Chainsaw Maintenance Guide

If your Poulan chainsaw is leaking gas, it could be time to change the fuel line. Fuel lines can become brittle and crack over time, causing fuel leaks and air to enter the fuel system. This can cause the engine to run erratically, die, or not start at all. To replace the fuel line, you'll need to drain the fuel tank, remove the cylinder shield, disconnect the spark plug wire, remove the air filter housing, remove the carburetor, and then remove and replace the fuel line. You can find Poulan chainsaw fuel line replacement kits online.

Drain the fuel tank

To drain the fuel tank of your Poulan chainsaw, you will need to remove the fuel cap and empty the tank into an approved storage container. This should be done in a well-ventilated area.

First, locate the fuel cap. Once found, remove it and set it aside. Now, you can start draining the excess fuel from the tank into your chosen container. It is important to do this carefully and slowly to avoid any spillages. Once the tank is empty, you can move on to the next step of changing the fuel line.

If your chainsaw won't start, it could be due to clogged or damaged fuel lines. Over time, the fuel lines can crack, restricting fuel flow and preventing the engine from starting. Therefore, it is important to regularly check the fuel lines for any signs of damage and replace them if necessary.

Remove the top cover

To remove the top cover of your Poulan chainsaw, you will need to first drain any excess fuel from the tank. Place a receptacle under the fuel tank to catch the fuel.

Once the fuel is drained, locate the three screws securing the top cover to the saw and remove them with a Phillips-head screwdriver. With the screws removed, you can now lift the top cover away from the saw.

It is important to work in a well-ventilated area when performing this task, as you will be exposed to gasoline fumes. Always use caution when working with gasoline, as it is highly flammable. Be sure to wear work gloves and eye protection for your safety.

Now that the top cover is removed, you can begin working on replacing the fuel line.

Remove the air filter housing

To remove the air filter housing, you will need to first remove the air filter cover. Once the cover is off, you can then remove the air filter itself from the housing.

Next, you will need to remove the screw that secures the air filter housing to the engine. There is usually only one screw, but it's important to check your specific model to be sure. After removing the screw, there will be two nuts that also secure the housing to the engine. Remove these nuts and then carefully lift the air filter housing away from the carburetor assembly.

Now that the air filter housing is removed, you can continue with the next steps to replace the fuel line.

It is important to note that you should always exercise caution when performing any type of repair or maintenance on a chainsaw. Ensure you are wearing proper protective gear and that you have a well-lit and ventilated workspace.

Remove the carburetor

To remove the carburetor of a Poulan chainsaw, you will need a 7/16-inch socket driver.

First, pull and hold the throttle trigger to expose the throttle linkage attachment point on the trigger. Then, disconnect the linkage from the throttle trigger. Next, disconnect and remove the throttle linkage from the carburetor.

Now, you will need to remove the carburetor assembly from the mounting bolts. Slide the carburetor away from the engine, being careful not to bend the throttle linkage or damage the gas lines. Use long-nosed pliers to disconnect the fuel intake line from the carburetor.

As a tip, for accurate reassembly, take digital photos of the throttle linkage on the carburetor and the gas line connections.

Remove the fuel return line

To remove the fuel return line, first drain any excess fuel from the tank. Then, remove the top cover by taking out the three screws that secure it to the chainsaw. Next, remove the air filter housing. Take off the air filter cover, remove the air filter, and then remove the screw that holds the air filter housing to the engine. Finally, take out the two nuts that secure the housing to the engine and lift it away from the carburetor assembly.

Now you can remove the carburetor. To do this, pull and hold the throttle trigger to expose the throttle linkage attachment point. Disconnect the linkage from the throttle trigger and then from the carburetor. Slide the carburetor assembly off the mounting bolts and away from the engine. Use long-nosed pliers to disconnect the fuel intake line from the carburetor.

The next step is to disconnect the fuel return line from the primer bulb. This line is secured inside the fuel tank by a plastic compression fitting. To remove it, you will need a good pair of hemostats. Use snippers or scissors to cut the return fuel line as close to the fuel tank as possible. Remove the fuel cap, and then use the hemostats to remove the compression fitting and the remainder of the return fuel line from the inside of the fuel tank. Finally, use a utility knife to cut the old fuel line away from the plastic fitting—this fitting will be reused.

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