Replacing Poulan 260 Pro Fuel Line: A Step-By-Step Guide

The Poulan 260 Pro is a chainsaw that requires regular replacement of its fuel line and fuel filter to ensure optimal performance. The fuel line is a crucial component that connects the gas tank to the carburetor, facilitating the flow of fuel to the combustion chamber. Over time, the fuel line can deteriorate due to constant contact with gasoline, leading to cracks and potential fuel leaks. Additionally, dried-out gas deposits from prolonged storage can also affect the fuel line's integrity. When replacing the fuel line, it is essential to follow the manufacturer's guidelines and exercise caution when working with open gasoline.

Drain the fuel tank and run the engine until it dies

To replace the fuel line on a Poulan 260 Pro, you must first drain the fuel tank. This is a necessary step to ensure that you are working with a safe, empty tank before you begin any work on the engine.

To do this, locate the drain plug at the bottom of the fuel tank. Place a receptacle underneath to catch the fuel, then remove the plug. Allow the fuel to drain completely before proceeding.

Once the tank is drained, replace the drain plug. Now, start the engine and let it run until it dies. This will burn off any remaining fuel in the lines and carburetor, ensuring that the fuel system is entirely empty before you begin disassembling and replacing the fuel line.

This step is crucial for safety, as you do not want to be working with a full tank of highly flammable fuel. It also ensures that you do not spill fuel when you begin to disassemble the engine and remove the fuel lines.

By running the engine until it dies, you are ensuring that the engine has no fuel left to continue running, which indicates that the fuel lines and carburetor are now empty. You can then proceed to the next steps of replacing the fuel line on your Poulan 260 Pro, which are detailed in the sources provided.

Remove the cylinder cover to access the air filter and carburetor

To remove the cylinder cover and access the air filter and carburetor, you will need a screwdriver. The cylinder cover is located on the top of the saw. Once you have removed it, you will be able to see and locate the fuel lines connected to the carburetor.

The air filter is located underneath the air filter cover, which can be removed by unscrewing the screws securing it to the engine. The carburetor is located underneath the air filter and is also secured to the engine by screws.

Before beginning this process, ensure that you have drained any excess fuel from the tank and removed the top cover of the saw. It is also important to work in a well-ventilated area when carrying out this process.

Cut the new fuel line to the proper length

To cut the new fuel line to the proper length, you must first align the ends of the old and new fuel lines. Then, 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.

When cutting the new fuel line, it is important to ensure that the length is accurate. If the fuel line is too long, it can be pulled up from inside the tank. If the line is too short, it may not reach the necessary components and may need to be trimmed.

Additionally, the fuel line should be cut at an angle to facilitate its insertion into the fuel tank. This angled cut will make it easier to thread the line through the mounting hole and into the tank.

It is also important to consider the size of the fuel line. The fuel line should be the exact same size as the one being replaced, including both the inner and outer diameters. This is crucial to ensure a proper fit and to prevent leaks.

By following these steps and considerations, you can cut the new fuel line to the proper length when replacing the fuel return line on a Poulan 260 Pro chainsaw.

Thread the new fuel line through the mounting hole in the fuel tank

To thread the new fuel line through the mounting hole in the fuel tank of your Poulan 260 Pro, follow these steps:

Firstly, cut the new fuel line at an angle. This will make it easier to insert into the fuel tank. You can also apply a thin layer of lubricant to the end of the line to help guide it through. Next, push the cut end of the fuel line into the hole inside the gas tank. You can use a wire to help guide it and provide leverage. Thread the line through until you can see it appearing out of the back end of the carburetor.

Now, cut off any excess line with scissors or a utility knife, ensuring you leave enough line to work with. Pull the line back through the tank, being careful not to pull it all the way out. You will need to install the plastic compression fitting and the new weighted filter onto the line. The filter should be extended to the furthest end of the fuel tank bottom. Now, pull the line back into the tank, ensuring the filter rests on the bottom and is able to swing around to maintain contact with the fuel.

Finally, connect the new fuel return line to the primer bulb assembly.

Reinstall the carburetor and connect the fuel line

To reinstall the carburetor and connect the fuel line, follow these steps:

Firstly, connect the incoming fuel line to the intake nipple on the bottom of the carburetor. This is usually green. Next, connect the fuel tank purge line to the outlet on the top of the carburetor. Now, slide the carburetor onto the two mounting posts on the engine.

At this point, you should connect the carburetor to the intake tube and press the carburetor assembly toward the engine until the intake tube is fully seated against both components. Then, connect the throttle linkage to the carburetor linkage. Pull and hold the throttle trigger to expose the attachment point for the trigger portion of the throttle linkage. Finally, connect the throttle linkage to the throttle trigger.

It is important to ensure that all fuel lines are clear of the mounting area of the carburetor and throttle function.

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