Replacing Husqvarna 235'S Fuel Line: A Step-By-Step Guide

If your Husqvarna 235 chainsaw is leaking gas, it's likely that you have a carburetor issue or a fuel line problem. To replace the fuel line, you'll first need to remove the top cover and check the fuel line condition. If the problem is with the return line from the primer bulb to the fuel tank, you can replace just that single fuel line, but it's recommended to replace all the lines at once. Unfortunately, accessing the carburetor on the Husqvarna 235 chainsaw requires taking apart a portion of the saw. This involves removing the handle assembly, disconnecting the throttle linkage, and taking off a part of the case. Once you have access to the carburetor, you can disconnect the fuel lines and install new ones. When reinstalling the carburetor, ensure the gasket is still in place, or the engine may not start or run poorly.

How to change the fuel line on a Husqvarna 235 chainsaw

Removing the handle assembly

To remove the handle assembly of your Husqvarna 235 chainsaw, you will need to follow these steps:

Firstly, locate the throttle linkage and disconnect it from the handle assembly. This will allow you to separate the handle assembly from the rest of the chainsaw. Once the throttle linkage is disconnected, you can carefully lift or slide the handle assembly away from the body of the chainsaw.

Next, you will need to remove the screws and nuts that secure the air filter base and the carburetor to the engine. Make sure you have a safe place to keep these screws and nuts, as you will need them again when reassembling the chainsaw. With the screws and nuts removed, carefully lift or slide the air filter base and carburetor away from the engine, giving you access to the fuel lines.

At this point, you should be able to see the fuel lines connected to the carburetor. Carefully disconnect these fuel lines, taking note of their routing for reassembly. With the fuel lines disconnected, you can now remove the carburetor entirely by sliding it off the studs.

Now that the carburetor and fuel lines are out of the way, you can focus on the handle assembly. Carefully inspect the assembly for any remaining fuel lines or connections that need to be disconnected. Once you are sure that all fuel lines are disconnected, you can proceed to remove the handle assembly from the chainsaw.

Take note of any wires, cables, or other components that may be attached to the handle assembly, and carefully disconnect them if necessary. With all connections removed, you should now be able to lift or slide the handle assembly away from the chainsaw body.

Disconnecting the throttle linkage

Firstly, remove the handle assembly. This is a necessary first step to gain access to the throttle linkage. The handle assembly can be removed by unscrewing the bolts or fasteners that hold it in place. Make sure to keep the screws or bolts in a safe place so they don't get lost.

Once the handle assembly is removed, you will be able to see the throttle linkage. The throttle linkage is the mechanism that connects the throttle trigger to the carburettor. It is usually a metal rod or cable that transfers the movement of the trigger to the carburettor, controlling the engine speed.

To disconnect the throttle linkage, locate the point where it is attached to the carburettor. This is usually done by removing any screws, clips, or clamps that hold the linkage in place. Be careful not to lose any small parts during this process. You can use a screwdriver or a pair of pliers to carefully remove them.

After detaching the linkage from the carburettor, make sure to also disconnect it from the throttle trigger itself. This will give you more room to work on the fuel line replacement. Again, be careful not to lose any small parts and use the appropriate tools to remove any fasteners.

Once the throttle linkage is disconnected, set it aside and proceed with caution. It is important to note that the throttle linkage is a delicate mechanism, and any damage to it can affect the performance of your chainsaw. Be mindful of how it was attached so that you can properly reassemble it later.

By following these steps, you will have successfully disconnected the throttle linkage on your Husqvarna 235 chainsaw, allowing you to access and replace the fuel line. Remember to keep all the parts organised and be gentle during the process to avoid any damage to the throttle linkage or surrounding components.

Accessing the carburetor

To access the carburetor of your Husqvarna 235 chainsaw, you will need to remove the top cover to check the fuel line condition. If the problem is with the return line from the primer bulb to the fuel tank, you can replace the single fuel line or all the lines at once. Unfortunately, on the Husqvarna 235 chainsaw, you need to take a portion of the saw apart to access the carburetor.

First, remove the handle assembly and disconnect the throttle linkage from it. Then, remove the air filter retainer, the air filter itself, and the screws and nuts that hold the filter base and the carburetor to the engine. Now you can disconnect the fuel lines and slide the carburetor off the studs.

Disconnecting and reinstalling fuel lines

To disconnect and reinstall the fuel lines of your Husqvarna 235 chainsaw, follow these steps:

Firstly, remove the top cover to inspect the fuel line condition. If there is an issue with the return line from the primer bulb to the fuel tank, you can opt to replace just that line, but it is recommended to replace all the lines at once. As a second step, disassemble your chainsaw by removing the handle assembly and disconnecting the throttle linkage. Then, remove the air filter retainer, the air filter, and the screws and nuts holding the filter base and the carburetor to the engine.

Now, you can disconnect the fuel lines and carefully slide the carburetor off the studs. With the carburetor out of the way, you can start removing the old fuel lines and installing the new ones. To make this process easier, cut the lines at an angle and use bent pliers. If you need to install a plastic splice, cut off the angled piece and insert the splice, then pull on the line until it stops. Make sure that the line is long enough for the fuel filter to reach the far side of the fuel tank.

Before reassembling the carburetor, ensure the gasket is still on the engine, or the engine may not start or run poorly. Also, make sure to connect the fuel filter line to the correct port. Once the carburetor is back in place, connect the line from the carburetor to the primer bulb.

Finally, check that the fuel system is working correctly by putting fuel in the tank and testing the primer to ensure the fuel flows from the tank to the carburetor, then the primer bulb, and finally back to the tank through the return line. Once you have confirmed that the fuel system is functioning properly, you can put all the parts back together.

Checking the fuel system

To check the fuel system, you should first fill the tank with fuel. Then, try to prime the chainsaw to ensure that the fuel is flowing as it should. It should flow from the tank to the carburetor, then to the primer bulb, and then back to the tank through the return line.

If the fuel is not flowing as it should, there may be an issue with the fuel lines or the carburetor. If the fuel lines are not switched, the next step is to check the fuel purge. To do this, identify which line has the filter and disconnect the other (fuel return) line at the carburetor. Then, press the purge bulb several times. If fuel spurts out of the fuel return port at the carburetor, the fuel purge is working. If not, move the fuel line with the filter to the other carburetor fuel port and repeat the test. If there is still no fuel, the issue may be with the fuel delivery from the tank, a blockage in the carburetor, or a faulty diaphragm.

It is important to ensure that the fuel system is working properly before reassembling the chainsaw. This will help to avoid any potential issues with the fuel flow once the chainsaw is put back together.

Additionally, when installing new fuel lines, it is recommended to cut the line at an angle and use bent pliers to help with the installation. For the fuel filter line, make sure that the line is long enough for the fuel filter to reach the far side of the fuel tank.

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