Replacing Poulan 221 Pro Fuel Line: A Step-By-Step Guide

If you're looking to replace the fuel lines on your Poulan 221 Pro, you've probably noticed that fuel lines are essential to the machine's functionality. Fuel lines are constantly in contact with gasoline, which means that over time, the gas will start to deteriorate the lines, making them more susceptible to cracks and breaks. This can cause fuel leaks and air to enter the fuel system, which can cause the engine to run erratically, die, or not start at all.

To replace the fuel lines, you'll need to purchase a replacement kit and follow a step-by-step guide to ensure you're taking the proper precautions and making the correct connections.

Drain the fuel tank

To drain the fuel tank of your Poulan 221 Pro, you will need to follow a few simple steps.

Firstly, locate the fuel tank and place a large pan or receptacle underneath it to collect the drained fuel. Make sure you have enough containers to collect all the fuel and avoid any spills.

Next, identify the drainage plug. This is usually a small bolt screwed into the tank. Use a spanner or socket wrench to carefully remove this bolt. The fuel will begin to drain out, so keep an eye on it and be prepared to wait, as it can take several minutes per gallon.

If your model doesn't have a drainage plug, you can try another method. Find the fuel lines, which are small, removable hoses underneath the tank. To drain the fuel using this method, you will need to turn the chainsaw on and off repeatedly to force the fuel out using the electric fuel pump.

Once the fuel tank is empty, carefully replace the drainage plug or reconnect the fuel lines, ensuring everything is hooked up properly.

If you prefer, you can also use a fuel siphon system to drain the fuel. Purchase a siphon pump from an auto store, making sure it's approved for use with combustible materials. Feed the hose into the fuel tank, and then pump the fuel into a container.

Remember to take appropriate safety precautions when working with fuel. Keep a fire extinguisher nearby and avoid any potential sources of sparks, such as lighters or screwdrivers.

Remove the top cover

To remove the top cover of your Poulan 221 Pro chainsaw, you'll need a screwdriver.

First, drain any excess fuel from the tank. Next, locate the three screws securing the top cover to the saw and remove them. Once the screws are removed, simply lift the top cover away from the saw.

Now that the top cover is removed, you can access the air filter housing and carburetor, which are the next steps in replacing the fuel return line.

Remove the air filter housing

To remove the air filter housing on a Poulan 221 Pro, follow these steps:

Firstly, remove the air filter cover. This will expose the air filter itself, which you should then carefully lift out of the housing. Next, locate the screw that secures the air filter housing to the engine and remove it. There will also be two nuts securing the housing to the engine, which you should also remove. Once these fasteners have been removed, you can carefully lift the air filter housing away from the carburetor assembly.

It is important to be careful when working with the air filter housing, as the engine and exhaust system can become very hot during operation. Always allow these components to cool before attempting any maintenance.

Remove the carburetor

To remove the carburetor from your Poulan 221 Pro chainsaw, you will need a few tools, including a Torx driver, hex wrench, long-nosed pliers, a ratchet/socket set, and a Phillip's screwdriver. You will also need a receptacle to drain the fuel into. Here is a step-by-step guide:

Drain the fuel:

First, drain the excess fuel from the fuel tank. This is an important safety precaution and will make the process less messy.

Remove the air filter:

• Loosen the knob securing the airbox cover.
• Remove the airbox cover from the saw.
• Pull the wire retaining bar down and away from the air filter.
• Lift the air filter out of the saw.

Remove the starter assembly:

• Remove the screws securing the starter assembly to the saw.
• Take out the starter assembly.

Remove the top cover:

• Use a hex wrench to remove the screws securing the top cover to the saw.
• Lift the top cover away from the saw.

Remove the air filter base:

• Take out the two nuts securing the air filter base to the mounting studs.
• Remove the screw securing the lower portion of the air filter base to the engine housing.
• Use long-nosed pliers to disconnect the ignition wires from the switch assembly.
• Lift the air filter out of the saw.

Remove the choke lever:

• Pivot the choke lever horizontally to disengage the choke lever linkage from the carburetor.
• Take out the choke lever.

Disconnect the throttle linkage:

• Depress the trigger lockout lever to expose the lower throttle linkage attachment point.
• Disconnect the throttle linkage from the trigger lockout assembly.
• Disconnect the throttle linkage from the carburetor.

Remove the carburetor:

• Slide the carburetor off the mounting studs.
• Use long-nosed pliers to disconnect the incoming fuel line from the carburetor.
• Use the pliers to squeeze the tabs on the inside of the purge bulb assembly and release the bulb from the engine housing.
• Disconnect the fuel return line from the purge bulb assembly using the pliers.
• Take out the carburetor (and purge bulb) from the saw.

Now that you have removed the carburetor, you can clean or replace it as needed. Remember to exercise caution when handling the fuel, and ensure you have a suitable receptacle to catch any excess fuel.

Remove the fuel return line

To remove the fuel return line of a Poulan 221 Pro chainsaw, follow these steps:

Firstly, drain any excess fuel from the tank. Next, remove the top cover by unscrewing the three screws that secure it to the saw, and lift it away. Then, remove the air filter housing by taking off the air filter cover and removing the air filter from inside it. Unscrew the air filter housing from 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 disconnect and remove the throttle linkage 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.

Finally, you can remove the fuel return line. Disconnect the fuel return line from the primer bulb. Cut the return fuel line as close to the fuel tank as possible, using snippers or scissors. Remove the fuel cap, and then use hemostats to remove the compression fitting and the remainder of the return fuel line from the inside of the fuel tank. Cut the old fuel line away from the plastic fitting, as this will be reused.

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