Replacing Stihl Chainsaw Fuel Line: A Step-By-Step Guide

If your Stihl chainsaw is not starting or the engine is dying, it may be time to replace the fuel line. The black rubber fuel lines can lose elasticity over time, causing them to collapse and reduce or stop the flow of fuel. This guide will take you through the steps to replace your Stihl chainsaw fuel line, from draining the fuel tank to lubricating and inserting the new fuel line.

How to Replace Stihl Chainsaw Fuel Line

Place the chainsaw on its right side, on a flat surface

To replace the fuel line of your Stihl chainsaw, you'll need to start by placing the chainsaw on its right side on a flat surface. This is an important step to ensure that you can access the fuel tank and that the chainsaw stays stable while you work.

Make sure your work surface is clear and clean, providing ample space for the chainsaw to lie flat on its right side. This will be the starting position for the repair, so it's important to get this step right. With the chainsaw on its right side, you should see the fuel tank cap pointing upward. This will be your primary point of access for the fuel line replacement.

The stability of the chainsaw in this position is crucial, as you'll be working with fuel, which can be hazardous. Ensure that the surface is flat and secure, and that the chainsaw is not at risk of tipping over or shifting during the repair process.

With the chainsaw securely in place, you can begin the process of replacing the fuel line. This will involve a series of steps, including draining the fuel, removing the old fuel line, and installing a new one. By following these steps and starting with a stable setup, you'll be able to complete the repair safely and effectively.

Remove the fuel cap and tilt the saw to drain the tank

To drain the fuel tank of your Stihl chainsaw, first place the chainsaw on its right side on a flat surface, with the fuel tank cap pointing upward. Remove the fuel cap from the tank by pressing the retainer ring inward and pulling it out.

Now, tilt the chainsaw over to drain the fuel from the tank into a container. It is important to use a container to catch the fuel so that it can be disposed of safely. You can use an old laundry detergent container or a gas can to collect the fuel. Alternatively, you can use a small plastic pump to pump the gas from the tank into a gas can.

If you are preparing the chainsaw for storage, you should also start the chainsaw and let it run to remove any leftover fuel from the carburetor.

Remove the fuel filter from the tank

To remove the fuel filter from the tank of your Stihl chainsaw, you'll need to first place the chainsaw on a flat surface. If your chainsaw still has fuel in the tank, siphon the fuel into a gas can or another approved container.

Now, you need to create a hook to reach into the tank and pull the filter out. You can use a metal clothes hanger, baling wire, or a piece of scrap house wiring for this. If you're using a metal hanger, cut off the bottom using wire cutters and bend one end into a hook with a pair of needle-nose pliers. If you're using wire, strip off any insulation to avoid contaminating the fuel tank, and form one end into a hook.

Reach the wire or hanger into the tank and hook it around the fuel filter. Pull the filter out towards the cap opening. You may need a flashlight to help you see inside the tank. Once you can grab the filter, hold the fuel line with one hand and work the filter off with the other. Be careful not to let the fuel line fall back into the tank, as it will be difficult to retrieve without the filter on the end. With the filter removed, you can now discard it and prepare to install a new one.

Turn the chainsaw upright and remove the air filter cover

To replace the fuel line of a Stihl chainsaw, you'll first need to turn the chainsaw upright on your work surface. This will give you access to the air filter cover at the rear of the engine.

The air filter cover is the part that protects the air filter from debris and dust when the chainsaw is in operation. It is important to remove this cover carefully to avoid damaging the air filter itself. With the chainsaw upright, locate the black knob on the rear of the engine. This knob secures the air filter cover in place. Turn it to the left to loosen and remove it.

Once the knob is loosened, you can pull off the air filter cover. It may take a bit of force to remove it, as it is designed to create a tight seal to protect the air filter. However, it should come off with a firm pull. Be careful not to drop or damage the cover, as you will need to reinstall it later.

Now that the air filter cover is removed, you can access the air filter itself. You will need to remove the air filter to replace the fuel line. This is done by prying upward on the two metal clips located on each side of the air filter with a flathead screwdriver. Once the clips are loose, pull the air filter straight up and out of its housing.

Remove the air filter housing and pull out the old fuel line

To remove the air filter housing, you will need to turn the chainsaw upright on your work surface. Locate the black knob on the rear of the engine and turn it left to pull off the air filter cover. Next, use a flathead screwdriver to pry the two metal clips upward on each side of the air filter. This will allow you to pull the air filter upward and out of the housing.

Once the air filter is removed, you will need to remove the two screws on the air filter housing. Use an 8-mm nut driver to remove these screws. After the screws are removed, simply pull the air filter housing straight off the chainsaw.

Now, you can access the old fuel line. Grasp the black fuel line with needle-nose pliers and pull it off the carburetor. Be sure to hold the chainsaw securely while doing this.

Turn the chainsaw onto its side with the fuel tank pointing upward. Locate the old fuel line inside the fuel tank and grasp it with the needle-nose pliers. Gently pull the old fuel line out of the tank, being careful not to damage any other components.

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