Replacing The Fuel Tank On Your Stihl Chainsaw: Step-By-Step Guide

If you're looking to replace the fuel tank on your Stihl chainsaw, you're in the right place. In this guide, we'll walk you through the process step by step, so you can get your chainsaw running like new again. But before we dive into the details, it's important to note that the fuel tank on a Stihl chainsaw is surrounded by other parts, so you'll need to disassemble the saw to access and replace the tank. Don't worry, though; the entire process only requires basic tools that you may already have on hand. So, whether you're an experienced handyman or a novice, follow these instructions carefully, and you'll be able to tackle this repair project with confidence.

Drain the fuel tank

To drain the fuel tank of your Stihl chainsaw, you must first place the chainsaw on a flat surface. Place a gas can next to the fuel tank and remove the fuel tank cap by twisting it counterclockwise. Insert a hand siphon into the tank and place the opposite end into the gas can. Siphon the fuel from the chainsaw into the gas can.

Alternatively, you can tilt the chainsaw over a container to drain the fuel tank and avoid spillage or wastage. If you are removing the fuel filter, you can use a metal hook to pull it out of the tank.

It is important to note that Stihl recommends using an approved fuel container for draining and storing fuel.

Remove the old fuel line

To remove the old fuel line from your Stihl chainsaw, you will need to first locate the old gas line. It is usually found near the fuel tank and carburetor. Once you have found the old gas line, you will need to disconnect it from both the fuel tank and the carburetor. You can carefully use a pair of pliers to loosen and remove the clamps securing the gas line.

When removing the clamps, it is important to use pliers that provide a firm grip to avoid any damage to the components. You can also use a fuel line removal tool, which is designed to grip the fittings and push back the retaining tabs for a smoother process.

After removing the clamps, slowly pull the gas line out from both ends. Be careful not to damage any other components during this process. Take note of the routing and positioning of the old gas line, as you will need to replicate this when installing the new one.

Before disposing of the old gas line, make sure to drain any remaining fuel into an approved fuel container. This will prevent any accidental fuel spillage or wastage. Always handle fuel with caution and ensure you are working in a well-ventilated area.

Install the new fuel line

To install the new fuel line, you will need a replacement gas line that is compatible with your Stihl chainsaw model. You can purchase this from a Stihl dealer or a reputable chainsaw parts supplier. Ensure the new line is of high quality to avoid leaks or failures.

Before installing the new fuel line, check that it is the correct size and type for your specific Stihl chainsaw model. Refer to the product manual or consult a professional if you are unsure.

Now, carefully insert one end of the new fuel line into the fuel tank, ensuring it is securely in place. Then, route the line through the correct path, making sure it is not kinked or twisted. Finally, connect the other end of the line to the carburetor, ensuring a tight fit.

To secure the new fuel line, use clamps or fittings that were removed earlier. Make sure the line is securely connected to both the fuel tank and the carburetor to prevent any leaks.

Test for leaks

Once you have finished replacing the fuel tank on your Stihl chainsaw, it is important to test for leaks. This is a crucial step to ensure the safety of the equipment and the user. Here is a detailed guide on how to perform a leak test:

• Prepare the Chainsaw: Place the chainsaw on a flat, level surface to ensure stability during the test. Ensure that the chainsaw is turned off and has cooled down completely before proceeding.
• Inspect the Fuel Tank: Carefully examine the newly installed fuel tank for any signs of damage, cracks, or imperfections. Look for any areas where fuel might escape, including the seams, joints, and connections.
• Fill the Fuel Tank: Fill the fuel tank with the appropriate type and amount of fuel. Refer to your Stihl chainsaw's user manual for the recommended fuel type and capacity.
• Observe for Leaks: With the fuel tank filled, carefully observe the chainsaw for any signs of fuel leakage. Pay close attention to the areas where the fuel tank connects to the rest of the chainsaw, including the fuel lines, grommets, and vent lines.
• Test in Different Positions: Place the chainsaw in various positions, such as upright and on its side. Some leaks may only occur when the chainsaw is in certain orientations. For example, a user on WoodBarter reported that their Stihl chainsaw leaked more when upright, so they stored it on its side.
• Wipe Down the Chainsaw: Use a clean cloth to wipe down the chainsaw, including the fuel tank and surrounding areas. This will help you identify any new leaks, as the cloth will absorb any fuel that might be leaking.
• Run the Chainsaw: Start the chainsaw and let it run for a few minutes. Observe the chainsaw during operation for any signs of fuel leakage. Pay attention to the areas around the fuel tank, carburetor, and vent lines.
• Post-Operation Inspection: After turning off the chainsaw, inspect it once again for any signs of fuel leakage. Wipe down the chainsaw with a clean cloth to detect any residual fuel.

If, at any point during these steps, you observe fuel leakage, it indicates that there may be an issue with the fuel tank installation or a problem with a specific component. It is important to address any leaks before using the chainsaw, as fuel leakage can pose safety hazards and damage the equipment. If you are unable to identify the source of the leak or resolve the issue, it is recommended to seek assistance from a qualified technician or a Stihl authorized service center.

Reassemble the chainsaw

Now that you have successfully removed the fuel tank from your Stihl chainsaw, it is time to put everything back together. Here is a detailed guide on how to reassemble your chainsaw:

• Start by placing the new fuel tank into the chassis. Ensure that the tank is securely seated in the correct position.
• Reattach the intake manifold to the top of the fuel tank. Make sure the rubber flange is properly seated and secured.
• Reinstall the engine cylinder shroud by connecting the spark plug wire and screwing it into place.
• Slide the carburetor sleeve back into the center intake manifold box opening.
• Reconnect the short circuit and ground wire connectors to the rear handle stop switch contact springs.
• Reattach the fan housing assembly using the retaining screws.
• Place the saw on its right side with the ignition facing up. Reinsert the rear annular buffer plug into the engine chassis and tighten the retaining screw.
• Flip the saw onto its bottom. Reinstall the chain sprocket cover onto the chassis and secure it with the retaining nuts using a socket wrench.
• Reinstall the cutting chain around the chain bar, chain sprocket, and engine chassis.
• Secure the chain tensioner plate and chain catcher using their respective retaining screws.
• Lay the saw on its left side. Reinsert the annular buffer plugs into the engine chassis with a flat-head screwdriver and tighten the retaining screws.
• Reconnect the ground wire grommet and ground circuit wires to the left side chassis using needle-nose pliers.
• Reattach the impulse hose to the nipple on the backside of the intake manifold.
• Reinstall the carburetor by sliding it onto the mounting studs and securing it with the retaining nuts.
• Reattach the carburetor adjusting screws' rubber grommet to the right-side carburetor body.
• Connect the fuel hose to the inlet elbow fitting.
• Reinstall the air filter assembly by screwing in the two slotted retaining nuts.
• Clip the choke and throttle linkage rods back onto the carburetor choke and throttle plastic linkages.
• Lower the carburetor box and rotate the twist lock retaining screw clockwise to secure it.
• Refill the fuel tank with Stihl two-stroke engine fuel, mixing 50 parts unleaded gasoline to 1 part engine oil.
• Reattach the fuel tank cap.

Once you have completed these steps, your Stihl chainsaw should be fully reassembled. Before starting the chainsaw, it is important to check for any fuel leaks. Follow the manufacturer's instructions for priming the chainsaw, then inspect for any signs of leaking fuel, such as dripping or a strong odour. If you notice any leaks, go back and double-check all the connections, making any necessary adjustments.

If there are no leaks, you can confidently start the chainsaw and resume your yard work. Remember to always follow safety precautions when working with power tools and fuel. Wear safety goggles, gloves, and long sleeves to protect yourself from debris and fuel contact. Always work in a well-ventilated area to avoid inhaling fumes.

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