Sylvie Willis
Owning a Poulan chainsaw comes with the responsibility of maintaining it. One of the most important parts of the chainsaw is the fuel line, which supplies gasoline to the engine. Over time, the fuel line can become brittle and break into small pieces, or become clogged with hardened gasoline. This can cause gas leaks, which can be dangerous. Therefore, it is important to know how to replace the fuel line. This is a simple task that can be performed by anyone with the proper instructions.
How to Run Fuel Lines on a Poulan Chainsaw
| Characteristics | Values |
|---|---|
| Fuel line replacement | A simple task that can be performed by a novice with proper instructions |
| Tools required | Paper towels, long needle-nose pliers, hemostats, flat-head screwdriver, spudger, snippers/scissors, utility knife, scrap wire |
| Preparation | Disconnect spark plug wire from spark plug, empty fuel tank, remove screws holding outer housing in place |
| Fuel line removal | Disconnect fuel line from primer bulb, remove fuel cap, remove compression fitting, cut old fuel line, remove choke lever, disconnect throttle linkage, slide out carburetor assembly, remove fuel filter |
| Fuel line installation | Measure and cut new fuel line, attach to carburetor and primer bulb, thread through mounting hole, install compression fitting, pull through fuel tank, reattach primer bulb and carburetor, replace screws and cover |
| Notes | Ensure correct size and length of fuel line, perform repair in a well-ventilated area, replace primer bulb to avoid potential issues |
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What You'll Learn
Replacing the fuel return line
To replace the fuel return line on a Poulan chainsaw, you will need to first drain the fuel tank. Then, disconnect the fuel return line from the primer bulb. The fuel return line is secured inside the fuel tank by a plastic compression fitting, which prevents the line from being accidentally pulled out of the tank. Using a good pair of hemostats, remove the compression fitting and the remainder of the return fuel line from the inside of the fuel tank. Use snippers or scissors to cut the return fuel line as close to the fuel tank as possible.
Next, use a utility knife to cut the old fuel line away from the plastic fitting. You will be reusing the plastic fitting, so be careful not to damage it. Now, take your new fuel line and cut it to the same length as the original fuel line. Cut an angle on one end of the new fuel line, which will make it easier to insert into the fuel tank.
Now, you are ready to install the new fuel return line. Thread the angled end of the new fuel line through the mounting hole on the fuel tank. Pull the new fuel line from the inside of the fuel tank through the mouth of the tank, being careful not to pull it completely out of the mounting hole. Pull the line just far enough so that you can install the plastic compression fitting. Use snippers 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.
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 and secures the new fuel line. Ensure that the new fuel line is securely connected to the primer bulb, and you're done!
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Disconnecting the fuel return line from the primer bulb
The fuel return line is secured inside the fuel tank by a plastic compression fitting, which prevents the line from being accidentally pulled from the tank. To disconnect the fuel return line from the primer bulb, you will need a good pair of hemostats, snippers or scissors, and a utility knife.
First, use the snippers or scissors to cut the return fuel line as close to the fuel tank as possible. Remove the fuel cap and, using the hemostats, remove the compression fitting and the remainder of the return fuel line from the inside of the tank. Next, use the utility knife to cut the old fuel line away from the plastic fitting. You will be reusing the fitting, so be careful not to damage it.
Now, you need to prepare the new fuel line. 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. Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Using hemostats, pull the new line through the mouth of the tank, being careful not to pull the line completely out of the mounting hole. Pull the line just far enough so that you can install the plastic compression fitting.
Use snippers or scissors to square the end of the new fuel line, removing the angle that was cut earlier. Install the plastic fitting onto the end of the new line. Now, install the plastic fitting and the new fuel line back into the fuel tank. From the outside of the tank, use the hemostats to pull the fuel return line until the plastic fitting engages the inside of the tank, securing the new line.
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Installing a new fuel return line
To install a new fuel return line on a Poulan chainsaw, you must first purchase the right size of the fuel line for your chainsaw model. The fuel return line is secured inside the fuel tank by a plastic compression fitting, which prevents the line from being accidentally pulled from the fuel tank.
Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Using hemostats, pull the new fuel line from the inside of the fuel tank through the mouth of the fuel 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 snippers 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. Install the plastic fitting and the 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 and secures the new fuel line to the tank.
Connect the new fuel return line to the primer bulb assembly. Reinstall the carburetor and connect the incoming fuel line (usually green) to the intake nipple on the bottom of the carburetor. 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.
Finally, 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.
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Replacing the primer bulb
To replace the primer bulb on a Poulan chainsaw, you will first need to disconnect the fuel return line from the primer bulb. The fuel return line is secured inside the fuel tank by a plastic compression fitting. This fitting prevents the line from being accidentally pulled from the fuel tank. Using a good pair of hemostats, remove the compression fitting and the remainder of the return fuel line from the inside of the fuel tank.
Next, use a utility knife to cut the old fuel line away from the plastic fitting. You will be reusing the fitting, so be careful not to damage it. Cut the new fuel line to the length of the original fuel line. Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Using hemostats, pull the new fuel line from the inside of the fuel tank through the mouth of the fuel 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 snippers 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. Install the plastic fitting and the 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.
You can purchase a primer bulb replacement for your Poulan chainsaw from online retailers. The price of the replacement bulbs varies from $8.79 to $25.22.
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Replacing the fuel filter
The fuel filter on a Poulan chainsaw should be inspected often and replaced at least yearly. If the fuel filter becomes clogged, the flow of fuel will be restricted, causing the engine to not start, run poorly, or die sporadically.
To remove the fuel filter, first, remove the fuel cap from the fuel tank. Then, make a hook out of a sturdy wire and use it to retrieve the fuel line containing the fuel filter from inside the tank. Take the fuel filter off the fuel line using long-nosed pliers.
When installing the new fuel filter, attach it to the fuel line and then tuck the line and the new filter into the fuel tank. Finally, reinstall and tighten the fuel cap.
It is important to ensure that you have the correct size of the fuel line when replacing it. The line must fit very snugly through the hole in the tank.
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Frequently asked questions
If your chainsaw has old fuel lines, they might be cracked or damaged. Over time, the gas will begin to harden and deteriorate the fuel lines, making them easily cracked or broken.
First, remove the spark plug wire from the spark plug to prevent accidental ignition. Then, empty the fuel from the gas tank and remove the screws holding the outer housing in place. Loosen the screws holding the carburetor in place, remove the fuel line, and attach a new filter to the end of the tubing. Drop the new fuel filter and tubing into the fuel tank and reattach the carburetor by screwing it back into place.
To remove the fuel lines, use a flat-head screwdriver or spudger to disconnect the fuel lines from the carburetor. Then, pull the carburetor assembly off the mounting bolts and away from the engine.
Thread the angled end of the new fuel line through the mounting hole on the fuel tank. Use hemostats to pull the new line through the mouth of the fuel tank, being careful not to pull it out completely. Square off the end of the fuel line and install the plastic compression fitting. Secure the new fuel line and fitting to the tank by pulling on the fuel return line with hemostats.
