Replacing Poulan Chainsaw's Fuel Line: Step-By-Step Guide

If you need to replace the fuel line on your Poulan chainsaw, you'll first need to drain the fuel tank and remove the top cover and air filter housing. You'll then need to disconnect the fuel intake line from the carburetor and remove the fuel return line from the primer bulb. Be sure to cut the return fuel line as close to the fuel tank as possible. Next, you'll need to cut the new fuel line to the proper length, making sure to add the length of the piece of fuel line that was 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. Finally, thread the angled end of the new fuel return line through the mounting hole on the fuel tank and pull it through using hemostats. Be careful not to pull the line completely out of the mounting hole.

Removing the fuel tank

To remove the fuel tank from your Poulan chainsaw, you will need to split the two housings. This will allow you to access and remove the fuel tank.

Firstly, remove the clutch cover side of the case by taking off the bar nut and the screw at the rear of the handle. This will expose the fuel tank, which you can then remove as a whole and work on outside of the main saw body.

Alternatively, you can try removing the cover off the chain side of the saw and sliding the tank out. However, this method may not provide enough access to the tank and fuel lines.

Once you have removed the fuel tank, you can begin the process of replacing the fuel lines and filter. It is recommended to also replace the carburetor, filter, and fuel lines together.

Using hemostat pliers to pull the fuel line through

Hemostat pliers are a great tool to use when replacing the fuel line on a Poulan chainsaw. They are perfect for getting into tight spaces and can be useful for pulling the new fuel line through the holes in the fuel tank.

To do this, first, cut the new fuel line at an angle to make it easier to feed into the tank. Then, thread the angled end of the new fuel line through the mounting hole in the tank. Next, use the hemostat pliers to grab the new fuel line from the inside of the tank and pull it through the mouth of the tank. Be careful not to pull the line all the way out of the mounting hole. Pull it just far enough so that you can install the plastic compression fitting.

Now, 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, and then feed the line and fitting back into the fuel tank. Finally, use the hemostat pliers once more to pull the fuel line from the outside of the tank until the plastic fitting engages with the inside of the tank, securing the new fuel line in place.

Hemostat pliers are a handy tool to have when working on small engines, and their thin, elongated profile makes them ideal for working with fuel lines.

Cutting the fuel line at a sharp angle

First, make sure you have the necessary tools, which include a utility knife, hemostats, and snippers or scissors.

Begin by draining any excess fuel from the tank. Then, remove the top cover of the chainsaw by unscrewing the screws that secure it in place. With the top cover removed, you can access the air filter housing. Remove the air filter cover, the air filter itself, and then unscrew the air filter housing to 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 the carburetor, and then slide the carburetor assembly off the mounting bolts, away from the engine.

At this point, you can disconnect the fuel intake line from the carburetor using long-nosed pliers. Next, disconnect the fuel return line from the primer bulb. The fuel return line is secured inside the fuel tank by a plastic compression fitting. Removing this will require some patience and careful use of hemostats.

Use your utility knife to cut the old fuel line away from the plastic fitting, which will be reused. Now, for the new fuel line, cut one end at a sharp angle. This angled end will make it easier to insert into the fuel tank.

Thread the angled end of the new fuel line through the mounting hole on the fuel tank. Use hemostats to carefully pull the new fuel line through the mouth of the fuel tank. Be careful not to pull the line all the way out of the mounting hole. Pull it just far enough so that you can install the plastic compression fitting.

Finally, use snippers or scissors to square off the angled end of the fuel line, removing the angle that was cut earlier.

Using a wire to feed the fuel line through the tank

To replace the fuel line on a Poulan chainsaw, 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.

Begin by draining any excess fuel from the tank. Then, remove the top cover by unscrewing the three screws that secure it to the saw. Next, remove the air filter housing by taking off the cover, removing the air filter, and unscrewing the air filter housing from the engine.

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 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.

The next step is to 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 wire cutters or scissors. Remove the fuel cap and, using hemostats, 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.

Now, you can cut the new fuel line to the proper length. Align the ends of the old and new fuel lines, and 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, and cut an angle on one end to make it easier to insert into the fuel tank.

Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Use hemostats to pull the new fuel line from the inside of the fuel tank through the mouth of the tank. Be careful not to pull the line completely out of the mounting hole. Pull the line just far enough to install the plastic compression fitting. Use wire cutters or scissors to square 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, and then install the plastic fitting and 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, securing the new fuel line. Finally, connect the new fuel return line to the primer bulb assembly.

Reassembling the chainsaw

Once you have successfully removed the fuel tank, carburetor, and fuel lines, you can begin reassembling your Poulan chainsaw. Here is a step-by-step guide to help you through the process:

Step 1: Obtain a new fuel filter and fuel lines. It is recommended to replace the carburetor and gasket at the same time if possible. Ensure that all components are compatible with your Poulan chainsaw model.

Step 2: Carefully feed the new fuel line through the hole in the fuel tank. Cut a long taper (3-4 inches) at the end of the fuel line to make it easier to feed through the hole. Use needle-nose pliers to grab the tapered end and pull it through.

Step 3: Install the new fuel filter onto the fuel line. The fuel filter should be mounted on the smaller fuel line, typically the .080"/.140" size. Refer to your chainsaw's fuel line routing diagram for clarification.

Step 4: Connect the fuel line with the fuel filter to the fuel inlet nipple on the carburetor. Ensure that the carburetor is correctly positioned and secured in place.

Step 5: Reinstall the fuel tank. Depending on your chainsaw model, you may need to split the two housings to remove and reinstall the fuel tank. Ensure that the fuel lines are not kinked or bent during this process.

Step 6: Check that the fuel filter is positioned correctly inside the fuel tank. It should fall to the low spot in the tank, depending on how you hold the chainsaw. Cut the tip of the fuel line at a sharp angle to ensure it feeds into the tank smoothly.

Step 7: If your chainsaw has a return line, insert it about 1/2 inch into the fuel tank. Refer to your Poulan chainsaw manual or a fuel line routing diagram to identify the correct positioning of the return line.

Step 8: Once all components are in place, carefully examine the fuel lines to ensure they are not kinked or blocked. Double-check that all connections are secure and that the fuel tank is properly seated.

Step 9: Refill the fuel tank with the appropriate fuel mixture for your Poulan chainsaw. Refer to your chainsaw's user manual for the correct fuel type and ratio.

Step 10: Test the chainsaw by starting it and checking for any fuel leaks. Ensure that the chainsaw idles correctly and that there are no unusual sounds or performance issues.

Always exercise caution when working with power tools and flammable substances. Refer to your Poulan chainsaw's user manual or seek expert advice if you have any doubts or concerns during the reassembly process.

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