Replacing Fuel Line Assembly In Poulan Chainsaws: Step-By-Step Guide

If you need to replace the fuel line assembly on your Poulan chainsaw, you'll first need to drain the fuel tank. Next, you'll need to remove the top cover and air filter housing, before disconnecting the fuel intake line from the carburetor. You'll then need to remove the fuel return line from the primer bulb and cut the new fuel line to the proper length. Finally, you can install the new fuel return line, reinstall the carburetor, and put the air filter housing and top cover back in place.

Removing the fuel return line

Before you start removing the fuel return line, make sure you have the right tools for the job. You will need a Phillip's screwdriver, Torx drivers, hemostats, a utility knife, a ratchet/socket set, wire cutters or scissors, and long-nosed pliers. It is also recommended to have a receptacle to drain the fuel into.

First, drain any excess fuel from the tank. Then, remove the three screws securing the top cover to the saw and lift it away. Next, remove the air filter housing by taking off the cover, removing the filter, and unscrewing the housing from the engine.

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

To remove the fuel return line, disconnect it from the primer bulb. This line is secured inside the fuel tank by a plastic compression fitting, which will need to be removed using hemostats and a good deal of patience. Cut the return fuel line as close to the fuel tank as possible, then remove the fuel cap and the compression fitting. Finally, cut the old fuel line away from the plastic fitting, which will be reused.

Installing the New Fuel Return Line

To install the new fuel return line, thread the angled end of the line through the mounting hole on the fuel tank. Pull the line through the mouth of the tank using hemostats, but be careful not to pull it all the way out. Pull the line just far enough to install the plastic compression fitting. Square off the end of the fuel line, install the plastic fitting, and then put the fitting and the line back into the tank.

From the outside of the tank, pull the fuel return line until the plastic fitting engages with the inside of the tank, securing the line. Finally, connect the new fuel return line to the primer bulb assembly.

Installing the new fuel return line

Now that you have removed the old fuel return line, it is time to install the new one. Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. You can use hemostats to pull the new line from the inside of the fuel tank through the mouth of the tank. Be careful not to pull the line all the way out of the mounting hole. Pull the line just far enough so that you can install the plastic compression fitting.

Use snippers or scissors to square off 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. Then, install the plastic fitting and the fuel line back into the fuel tank. From the outside of the fuel tank, use hemostats to pull the fuel return line until the plastic fitting engages the inside of the fuel tank. This action secures the new fuel line to the tank. Finally, connect the new fuel return line to the primer bulb assembly.

Reassembling the unit

Now that you have replaced the fuel line, it's time to reassemble your Poulan chainsaw. Here is a step-by-step guide to help you through the process:

Reinstall the carburettor:

• Connect the incoming fuel line (usually green) to the intake nipple on the bottom of the carburettor.
• Connect the fuel tank purge line to the outlet on the top of the carburettor.
• Slide the carburettor onto the two mounting posts on the engine.
• Connect the carburettor to the intake tube and press it towards the engine until the intake tube is fully seated against both components.
• Connect the throttle linkage to the carburettor linkage.

Reinstall the air filter housing:

• Slide the air filter housing over the carburettor mounting posts.
• Secure the air filter housing to the engine with the nuts.
• Secure the air filter housing to the carburettor with the screw.
• Install the air filter.
• Install the air filter cover.

Reinstall the top cover:

• Install the top cover onto the saw.
• Secure the top cover with the screws.

Your Poulan chainsaw is now reassembled and ready to be tested. Remember to exercise caution when working with power tools and always wear appropriate safety gear.

Tools required

The tools required to replace the fuel line assembly on a Poulan chainsaw include:

• A new fuel line kit, including a fuel filter and primer bulb
• A screwdriver
• Pliers, preferably needle-nose pliers
• Hemostats
• A utility knife
• Wire cutters or scissors
• A ratchet/socket set
• A receptacle for draining fuel

Some additional tools that may be useful include:

• WD-40
• Bent needle-nose pliers
• Lubricant

It is important to wear proper safety gear and follow safety protocols when working with a chainsaw.

Fuel line issues

Fuel lines are in constant contact with gasoline. Over time, the gas will begin to harden and cause the fuel lines to deteriorate. Even a small crack will create a potentially dangerous fuel leak, and will allow air into the fuel system. Air in the fuel system can cause the engine to run erratically, die, or not start at all.

If your Poulan chainsaw is experiencing fuel line issues, you will need to replace the fuel line assembly. This is a fairly straightforward process, but it requires careful handling of the fuel lines and other components. Here are the steps to replace the fuel line assembly:

Step 1: Drain the Fuel

Start by draining any excess fuel from the tank. This will prevent spills and reduce the risk of fire during the repair process.

Step 2: Remove the Top Cover and Air Filter Housing

Remove the screws securing the top cover to the saw and lift it away. Then, remove the air filter cover, air filter, and housing. Keep track of the screws and place the parts aside safely.

Step 3: Disconnect the Carburetor

Pull and hold the throttle trigger to expose the throttle linkage attachment point. Disconnect the linkage from the throttle trigger and the carburetor. Slide the carburetor assembly off the mounting bolts and away from the engine.

Step 4: Remove the Fuel Return Line

Disconnect the fuel return line from the primer bulb. Cut the return fuel line close to the fuel tank using wire cutters or scissors. Remove the fuel cap and, using hemostats, take out the compression fitting and the remainder of the return fuel line from the tank. Cut the old fuel line away from the plastic fitting, as this fitting will be reused.

Step 5: Prepare the New Fuel Line

Cut the new fuel line to the proper length by aligning it with the old fuel line. Remember to add the length of the piece cut from the plastic fitting. Cut an angle on one end of the new fuel line to make it easier to insert into the fuel tank.

Step 6: Install the New Fuel Return Line

Thread the angled end of the new fuel return line through the mounting hole in the fuel tank. Use hemostats to pull the line through the mouth of the tank, ensuring it is not pulled completely out of the mounting hole. Install the plastic compression fitting onto the end of the new fuel line, then insert the line and fitting back into the tank. Pull the fuel return line from the outside of the tank until the plastic fitting secures the new line in place. Finally, connect the new fuel return line to the primer bulb assembly.

Step 7: Reinstall the Carburetor and Air Filter Housing

Connect the incoming fuel line to the intake nipple on the carburetor and the fuel tank purge line to the outlet. Slide the carburetor onto the mounting posts, connecting it to the intake tube and carburetor linkage. Pull and hold the throttle trigger to expose the attachment point, then connect the throttle linkage to the trigger. Reinstall the air filter housing, air filter, and cover, securing them with the appropriate screws.

By following these steps, you can effectively replace the fuel line assembly on your Poulan chainsaw, addressing any fuel line issues and ensuring a smooth and efficient operation.

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