Replacing Fuel Line On Poulan Chainsaw: A Step-By-Step Guide

If you need to replace the fuel line on your Poulan chainsaw, you're not alone. Many people have faced the same challenge and shared their experiences online. The fuel line on a Poulan chainsaw can become damaged due to prolonged contact with gasoline, which can cause the line to harden, crack, or break over time. Replacing the fuel line typically involves removing the air filter and carburetor, cutting the new fuel line to the proper length, and installing it through the fuel tank. Depending on the model, you may need to remove the flywheel to access the fuel line. It is recommended to replace the carburetor, filter, and fuel lines together.

Removing the fuel return line

Before you start removing the fuel return line, make sure you have the right tools for the job. 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. You should also have a receptacle for draining fuel.

First, drain any excess fuel from the tank. Then, remove the top cover of the chainsaw by taking out the three screws that secure it and lifting it away. Next, remove the air filter housing. Take off the air filter cover, and remove the air filter itself. Now, unscrew the air filter housing from the engine, and lift it away from the carburetor assembly.

Pull and hold the throttle trigger to expose the throttle linkage attachment point. Disconnect the linkage from the throttle trigger, and then 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.

Now you're ready to remove the fuel return line. Disconnect the 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 use the hemostats to take out the compression fitting and the remainder of the return fuel line from inside the tank. Finally, cut the old fuel line away from the plastic fitting, which will be reused.

Drain the fuel

Before you begin to replace the fuel lines on your Poulan chainsaw, it is important to drain the fuel from the tank. Here is a step-by-step guide to help you through the process:

Firstly, you will need to gather the necessary tools and materials. For this step, you will require a container to catch the drained fuel, as well as a clean cloth to wipe down the chainsaw and prevent any contamination. It is important to prioritise safety during this process, so be sure to wear safety gloves and goggles to protect your hands and eyes from fuel and debris.

Once you have gathered the required tools, locate the fuel tank and remove the housing covering it. This will grant you easy access to the fuel lines and the tank itself. Turn off your chainsaw and ensure that it is cool to the touch before proceeding.

Now, you can begin to drain the fuel. Place your container underneath the fuel tank to catch the drained fuel. Depending on your model, you may need to use needle-nose pliers to pinch off the fuel line, preventing any further flow of fuel. You can then remove the fuel line from the backside of the fuel filter, allowing the fuel to drain into the container. Be sure to use a container that is large enough to hold the entire capacity of the fuel tank.

If your Poulan chainsaw model features a fuel cap, simply remove the cap and allow the fuel to drain into the container. This process may take some time, so be patient and allow the fuel to drain completely. Once the fuel has finished draining, you can proceed to the next step of replacing the fuel lines. Remember to dispose of the drained fuel in a safe and responsible manner.

By following these steps, you can effectively and safely drain the fuel from your Poulan chainsaw, preparing you for the next steps in the fuel line replacement process. Always prioritise safety and refer to your chainsaw's manual for specific instructions pertaining to your model.

Cut the new fuel line to the proper length

To cut the new fuel line to the proper length, you will need to first align the ends of the old fuel line and the new fuel line. 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—this will make it easier to insert the new line into the fuel tank.

Now, thread the angled end of the new fuel line through the mounting hole on the fuel tank. Use hemostats to pull the new 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.

Next, 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. Install the plastic fitting and the fuel line back into the fuel tank.

Finally, 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. This will secure the new fuel line to the tank.

Install the fuel return line

To install the fuel return line, start by threading the angled end of the new fuel return line through the mounting hole on the fuel tank. Use hemostats to pull the new line from the inside of the fuel tank through the mouth of the tank. Be careful not to pull the line all the way out of the mounting hole. Pull the line just far enough so that you can install the plastic compression fitting.

Next, use wire cutters 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. Then, install the plastic fitting and fuel line back into the fuel tank.

From the outside of the fuel tank, where the fuel line enters, use hemostats to pull the fuel return line until the plastic fitting engages the inside of the fuel tank. This action secures the new fuel line to the tank. Finally, connect the new fuel return line to the primer bulb assembly.

Reassembling the unit

Once you have successfully replaced the fuel line, you can now reassemble the unit. Here is a step-by-step guide:

• Reinstall the carburetor: Connect the incoming fuel line (usually green) to the intake nipple at the bottom of the carburetor. Then, connect the fuel tank purge line to the outlet on the top of the carburetor. Slide the carburetor onto the two mounting posts on the engine.
• Connect the carburetor to the intake tube: Press the carburetor assembly toward the engine until the intake tube is fully seated against both components.
• Connect the throttle linkage: 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.
• Reinstall the air filter housing: Slide the air filter housing over the carburetor mounting posts. Secure the air filter housing to the engine with the two nuts. Secure the air filter housing to the carburetor with the screw.
• Install the air filter and cover: Put the air filter back in, and then install the air filter cover.
• Reinstall the top cover: Place the top cover onto the saw and secure it with the screws.

Your Poulan chainsaw should now be fully reassembled with a new fuel line.

Frequently asked questions