Replacing The Fuel Line On Your Homelite Chainsaw

If you're looking to replace the fuel line on your Homelite chainsaw, you may be in for a challenging task. The process can vary depending on the model of your chainsaw, but in some cases, it may be necessary to completely disassemble the saw to access the fuel tank and line. This can involve removing the clutch, muffler, oil pump, and front carb assembly. However, some users have suggested that it is possible to access the fuel tank by removing the pull starter side, although this may not be the case for all models.

One recommended method for replacing the fuel line is to use a stiff wire with a hook to grab onto the fuel/oil line and guide it out through the tank opening. Additionally, ensuring that the tank is clean and free of oil and fuel residue can make it easier to work with. When installing the new fuel line, it is important to slide it through the grommet and ensure that it extends out of the gas cap hole. Attaching a fuel filter and ensuring it rests at the bottom of the tank is also crucial.

Removing the clutch, muffler, oil pump and front carb assembly

To replace the fuel line on a Homelite 240 chainsaw, you must first remove the clutch, muffler, oil pump, and front carb assembly. Here is a detailed guide on how to do this:

Removing the clutch:

• Purchase a 2-pin clutch removal tool. This is the correct tool for removing the clutch and will ensure you do not damage the saw or its parts.
• Insert the 2-pin tool into the exposed crankshaft. The pins should go on opposing sides of the clutch's centre crossbeam, pinching and gripping it.
• Use a rope or cord to stop the crankshaft from turning. Remove the spark plug and push about two feet of cord into the cylinder through the spark plug hole. Ensure the piston is on its upstroke and past the exhaust port opening before placing the cord to avoid damage to the cylinder and piston.
• Apply penetrating oil to the clutch a few hours or, ideally, a day before removal to help ease the process.
• Once the rope is in place, use a wrench with the 2-pin tool to remove the clutch.

Removing the muffler:

• The muffler should have a small hole in its centre—this is where you will find the screw that attaches the muffler to the chainsaw.
• Use an Allen wrench (also known as a hex key) to unscrew and remove the muffler.

Removing the oil pump:

• Remove the bar and chain, top cover, air filter, pull starter, and muffler.
• Flip the saw over and remove the four motor mount bolts.
• Lift the motor up and take note of the throttle cable and carb for reassembly.
• The oil pump is secured to the crankcase cap with two screws.

Removing the front carb assembly:

Slide the carburettor out of the choke lever. It may be helpful to refer to the Illustrated Parts List (IPL) for your model of chainsaw to identify the choke lever and carburettor.

Please note that this answer is based on guidance for similar Homelite chainsaw models. The process for removing these parts may vary slightly depending on your specific model. Always refer to the manufacturer's instructions or seek advice from a qualified technician if you are unsure.

Using a stiff wire with a hook to fish out the fuel line

To replace the fuel line on a Homelite chainsaw, you can use a stiff wire with a hook to fish out the old fuel line and pull the new one through.

First, cut the old fuel line with a nice lengthy taper and tie some fishing line near the end. Run the fishing line through the hole into the tank and fish it out through the filler opening with your finger, a screwdriver, forceps, or by simply wiggling it. You can also use a stiff wire with a hook on it to grab the fuel line and pull it out. Once you have removed the old fuel line, you can pull the new fuel line through the hole using the fishing line or stiff wire.

Before pulling the new fuel line through, apply a bit of oil to help it slide through more easily. Pull the line, trying to keep it perpendicular to the hole and rotating it as needed if it feels too tight. When you finally get the line through so you can grab it, you're almost done.

Now, slide the new fuel line through the grommet, making sure to slide enough line through so that it will extend out of the gas cap hole. Put the fuel filter on, then put the filter in the tank and pull the line back into the tank until the filter rests at the bottom. Finally, put the grommet back into the tank.

Cleaning the tank with soap and water before inserting a new fuel line

To clean your Homelite chainsaw's fuel tank with soap and water, use warm water and a liquid dish detergent like Palmolive. This will help to remove any oil and fuel residue. Ensure you clean the tank thoroughly, as any remaining residue will affect the bonding of the new fuel line.

Once the tank is clean, dry it thoroughly and prepare to insert the new fuel line. The new fuel line should be slightly smaller than the hole in the tank. Run an extra-long piece of this new line through the hole, and seal it with a generous amount of gold silicone rubber. Allow the silicone to cure for a day.

Next, move the line in and out by about a quarter of an inch to ensure the silicone fillets both the inside and outside of the fuel tank hole. Then, pull out the end of the fuel line that is inside the tank, and cut it to the desired length. Finally, attach a fuel filter to the end of the line.

Using a small amount of red rubber grease to help insert the fuel line

To replace the fuel line in a Homelite chainsaw, you'll need to remove the grommet from the tank. The grommet is the plastic or rubber piece that the fuel line passes through to enter the tank. Once the grommet is removed, you can slide the new fuel line through and cut it to the correct length. Before sliding the fuel line through the grommet, it is recommended to apply a small amount of red rubber grease to the fuel line. This will make it easier to insert the line through the grommet and into the tank.

Red rubber grease is a type of lubricant that is often used in automotive and mechanical applications. It is designed to be compatible with rubber and plastic materials, making it ideal for use in fuel systems. When applying the grease, use just enough to coat the end of the fuel line that will be inserted into the grommet. Too much grease can make a mess and may attract dirt and debris.

As you slide the fuel line through the grommet, be careful not to kink or bend the line, as this can restrict fuel flow. It is also important to ensure that the fuel line is securely seated in the grommet to prevent leaks. Once the fuel line is in place, you can re-insert the grommet into the tank and secure it in place.

By using a small amount of red rubber grease, you can make the process of installing the fuel line easier and help ensure a secure and leak-free connection.

Using a screwdriver to carefully insert the fuel line

To replace the fuel line on a Homelite chainsaw, you will need to carefully insert the new fuel line into the tank. This can be done using a screwdriver. Here are some detailed steps to guide you through the process:

Firstly, ensure you have the correct replacement fuel line for your specific Homelite chainsaw model. The fuel line should be the appropriate length and diameter to fit your chainsaw's fuel tank and carburetor. It is also recommended to have some form of lubrication, such as dish detergent, red rubber grease, or oil, to aid in the insertion process.

Now, remove the old fuel line from the tank. Cut the line with a nice, long taper and tie some fishing line near the end. This will help guide the new fuel line through the tank. Next, take your screwdriver and carefully insert it into the tank, using it to guide and feed the new fuel line through. Make sure to apply lubrication to the fuel line as you insert it, as this will make the process easier and help prevent damage to the line.

Take your time and work carefully, ensuring the fuel line is fed through smoothly and does not catch on any internal components. Once the fuel line is fully inserted, you can then attach the fuel filter and ensure it rests at the bottom of the tank. Finally, secure the fuel line in place by reinstalling the grommet or any other relevant components.

By carefully using a screwdriver to insert the fuel line, you can successfully replace the fuel line on your Homelite chainsaw, ensuring a smooth and damage-free installation process.

Frequently asked questions