Replacing Fuel Lines: Poulan Chainsaw Maintenance Guide

If you're having trouble with your Poulan chainsaw, it could be time to change the fuel line. This is a simple task that can be carried out by beginners and experts alike, and it could save you a trip to the dealer. This step-by-step guide will take you through the process of changing the fuel line in your Poulan chainsaw, covering everything from safety precautions to the tools you'll need and the steps to take.

How to Change Fuel Line in Poulan Chainsaw

Empty the fuel tank

Emptying the fuel tank of your Poulan chainsaw is a crucial step when replacing the fuel line. Here is a detailed, step-by-step guide on how to do it safely and effectively:

Before beginning, ensure you have the necessary safety equipment, including eye protection and gloves, and work in a well-ventilated area to avoid inhaling gasoline fumes.

First, remove the spark plug wire from the spark plug. This step is essential for safety, as it prevents accidental ignition of the chainsaw during the fuel line replacement process.

Next, place a suitable gas can or container below the fuel tank. Locate and unscrew the gas cap, being cautious not to spill any fuel. If there is a significant amount of fuel remaining in the tank, carefully pour it into the gas can for storage. It is important to handle gasoline with caution and store it in a safe location away from your work area.

Once the fuel tank is emptied, you can start the chainsaw and let it run until the engine dies. This step ensures that any excess gasoline left in the tank is burned off and doesn't leak out during the disassembly process.

After the engine has died, use a screwdriver to carefully remove the cylinder cover on the top of the saw, which protects the air filter and carburetor. Be cautious not to misplace any screws, as you will need to put them back during reassembly.

Now that the fuel tank is accessible, you can begin the process of replacing the fuel line by removing the fuel filter and fuel line assembly, as described in the next steps. Remember to work carefully and patiently throughout the process to ensure a successful fuel line replacement.

Remove the spark plug wire

To remove the spark plug wire from your Poulan chainsaw, locate the spark plug. This is usually found near the engine. Once you've located the spark plug, simply pull the spark plug wire away and detach it from the spark plug. This will prevent the chainsaw from accidentally igniting while you're replacing the fuel line.

It's important to take safety precautions when working with power tools. Before you begin any maintenance or repair work on your chainsaw, make sure the engine is turned off and the chainsaw is no longer running. This will reduce the risk of injury or accident.

Now that you've removed the spark plug wire, you can continue with the next steps of replacing the fuel line. Remember to work in a well-ventilated area to avoid inhaling gasoline fumes, and have a suitable container ready to catch any excess fuel that may spill or leak during the process.

Always refer to the manufacturer's guidelines when performing maintenance or repairs on your Poulan chainsaw. If you're unsure about any steps or procedures, consult a qualified technician or refer to a detailed repair guide for more comprehensive instructions.

Remove the cylinder cover

To remove the cylinder cover from your Poulan chainsaw, you will need to use a screwdriver. This cylinder cover is located on the top of the saw and protects the air filter and carburetor.

First, make sure that you have drained any excess fuel from the tank and disconnected the spark plug wire from the spark plug to prevent accidental ignition.

Next, locate the screws that hold the cylinder cover in place. There should be three screws securing the cover to the saw. Use your screwdriver to remove these screws and set them aside in a safe place. Once the screws have been removed, you can carefully lift the cylinder cover away from the saw.

With the cylinder cover removed, you will now be able to access the carburetor and fuel lines. Before proceeding with any further repairs or maintenance, it is important to take note of the orientation of the carburetor and fuel lines to ensure proper reassembly.

Now that the cylinder cover has been successfully removed, you can continue with the next steps of replacing the fuel lines. Remember to work in a well-ventilated area and exercise caution when handling any fuel-related components.

Remove the carburetor

To remove the carburetor of your Poulan chainsaw, you will need to first remove the spark plug wire from the spark plug to prevent accidental ignition. Then, empty the fuel tank into a gas can and store it away from your workspace.

Next, remove the screws that hold the outer housing of the chainsaw in place, and place the screws and housing to one side for replacement later. With the housing removed, you will be able to access the carburetor.

Before removing the carburetor, you will need to disconnect the fuel intake line and the fuel return line. To do this, follow these steps:

• Pull and hold the throttle trigger to expose the throttle linkage attachment point.
• Disconnect the linkage from the throttle trigger.
• Disconnect and remove the throttle linkage from the carburetor.
• Use long-nosed pliers to disconnect the fuel intake line from the carburetor.
• Disconnect the fuel return line from the primer bulb.
• Use hemostats to remove the compression fitting and the remainder of the return fuel line from inside the fuel tank.

Now that the fuel lines have been disconnected, you can remove the carburetor assembly by sliding it off the mounting bolts and away from the engine.

Install the new fuel line

To install the new fuel line, you will need a new fuel line, a plastic compression fitting, and tools such as hemostats, snippers or scissors, and long-nosed pliers.

First, cut the new fuel line to the proper length. Align the ends of the old and new fuel lines and add the length of the piece of fuel line that was cut from the plastic fitting. Cut the new fuel line to the length of the original fuel line. Cut an angle on one end of the new fuel line to make it easier to insert into the fuel tank.

Now, thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Using hemostats, pull the new line from the inside of the fuel tank through the mouth of the tank. Be careful not to pull the line completely out of the mounting hole. Pull the line just far enough to install the plastic compression fitting.

Next, use snippers or scissors to square the end of the fuel line, removing the angle that was cut earlier. Install the plastic fitting onto the end of the new fuel line. Install the plastic fitting and the fuel line back into the fuel tank.

From the outside of the fuel tank, where the fuel line enters, use hemostats to pull the fuel return line until the plastic fitting engages the inside of the fuel tank and secures the new line to the tank. Finally, connect the new fuel return line to the primer bulb assembly.

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