Ameer Randolph
If your Poulan chainsaw is leaking gas, it's probably time to replace the fuel lines. This is because, over time, the gas will begin to harden and deteriorate the fuel lines, making them easily cracked or broken. To replace the fuel lines, you'll need to buy a replacement fuel line kit and carefully follow a step-by-step guide to ensure a correct installation. This may include disconnecting the fuel return line from the primer bulb, cutting the fuel line, removing the fuel cap, and using tools like hemostats, scissors, or a utility knife.
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What You'll Learn
Disconnecting the fuel return line from the primer bulb
Firstly, use snippers or scissors to cut the return fuel line as close to the fuel tank as possible. Remove the fuel cap. Using hemostats, carefully remove the compression fitting and the remainder of the return fuel line from the inside of the fuel tank. You will need to use a utility knife to cut the old fuel line away from the plastic fitting. The fitting will be re-used, so make sure you don't damage it.
Now, you need to align the ends of the old and new fuel lines. Measure the length of the piece of fuel line that was cut from the plastic fitting. Cut the new fuel line to match the length of the original fuel line.
At this point, you can connect the new fuel return line to the primer bulb assembly. Plug one of the ports on the new primer bulb with your finger and press the primer bulb several times. If the bulb softens and deflates without returning to its original shape, you have identified the intake port. If the bulb hardens and won't allow further priming, you have identified the return port. Connect the shorter, incoming fuel line to the intake port on the new bulb.
Finally, connect the other end of the incoming fuel line to the carburetor, and then connect the fuel return line to the return port on the new primer bulb.
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Removing the fuel cap
To remove the fuel cap, you will need to first 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, carefully remove the compression fitting and the remainder of the return fuel line from the inside of the tank.
Now, use a utility knife to cut the old fuel line away from the plastic fitting. You will be re-using the plastic fitting, so ensure that you cut the fuel line as close to the tank as possible. Once the old fuel line has been removed, you can begin installing the new fuel return line.
Thread the angled end of the new fuel return line through the mounting hole on the fuel tank. Use hemostats to carefully pull the new line from the inside of the 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 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 fuel line. Now, install the plastic fitting and the fuel line back into the fuel tank. From the outside of the tank, where the fuel line enters, use hemostats to pull the fuel return line until the plastic fitting engages the inside of the tank and secures the new line.
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Installing the new fuel return line
To install the new fuel return line, begin by threading the angled end of the new fuel return line through the mounting hole on the fuel tank. Using hemostats, carefully pull the new fuel line from the inside of the fuel tank through the mouth of the tank. Ensure you do not pull the line all the way out of the mounting hole, only pulling it 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. Now, 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.
If you are having trouble getting the lines through the holes in the fuel tank, you can try using a thin piece of wire attached to a key ring. Thread the wire through the hole, attach the line cut to a sharp point to the wire, and then close the end of the wire with pliers. This should give the wire and fuel line enough clearance to pull through.
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Replacing the primer bulb and fuel lines
The primer bulb (or purge bulb) is used to manually pump fuel into the carburetor, which purges the air out of the carburetor. Over time, the primer bulb will harden and crack due to its constant contact with fuel. The fuel lines are also in constant contact with gasoline, which will cause them to harden and deteriorate over time, making them prone to cracking or breaking.
Step 1: Drain the Fuel
Drain any excess fuel from the tank.
Step 2: Remove the Top Cover
Remove the screws securing the top cover to the saw and lift it away from the saw.
Step 3: Remove the Starter Assembly
Remove the screws securing the starter assembly to the side of the saw and lift it away from the saw.
Step 4: Remove the Air Filter Housing
Remove the air filter cover and the air filter from the housing. Remove the screws securing the air filter housing to the engine and lift it away from the carburetor assembly.
Step 5: Disconnect the Fuel Lines
Use long-nosed pliers to disconnect the fuel lines from the primer bulb. Also, disconnect the choke lever and the fuel line from the carburetor.
Step 6: Identify the Ports
Plug one of the ports on the new primer bulb with your finger and press the primer bulb several times. If the bulb softens and deflates, you have identified the intake port. If the bulb hardens, you have identified the return port.
Step 7: Connect the Fuel Lines to the Primer Bulb
Connect one end of the incoming fuel line (the shorter line) to the intake port on the new primer bulb. Connect the other end of the incoming fuel line to the carburetor. Connect the fuel return line to the return port on the new primer bulb.
Step 8: Install the New Primer Bulb
Thread the fuel lines (connected to the new primer bulb) into the slot on the engine housing. Press the new primer bulb into the housing until it snaps into place.
Step 9: Install the New Fuel Return Line
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 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. 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.
Step 10: Secure the New Fuel Line
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 to the tank.
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Attaching the new fuel line to the carburetor
To attach the new fuel line to the carburetor, start by pulling out and removing the old fuel lines and fuel filter. Disconnect the fuel return line from the primer bulb. Cut the return fuel line as close to the fuel tank as possible using snippers or scissors.
Next, use a utility knife to cut the old fuel line away from the plastic fitting. Align the ends of the old and new fuel lines, and 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. Pull the new fuel line from the inside of the fuel tank through the mouth of the tank, using hemostats. Ensure you do not pull the line out of the mounting hole.
Square off the end of the new 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 fitting and the fuel line back into the fuel tank. Pull the fuel return line from the outside of the fuel tank using hemostats until the plastic fitting engages the inside of the fuel tank, securing the new fuel line.
Now, attach one end of the new fuel line to the incoming fuel port on the carburetor. Move the fuel line through the primer bulb housing and hold the primer bulb up to the fuel line. Mark the desired length and cut the fuel line to size. Attach the cut end of the primer fuel line to the intake port of the primer bulb, and then slide the carburetor back off the mounting bolts. Cut and remove the remaining old fuel lines by pulling them through the housing.
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Frequently asked questions
If your chainsaw is leaking gas from the engine, it's a good idea to check the fuel lines. Over time, the gas can cause the fuel lines to harden and deteriorate, leading to cracks and breaks.
First, disconnect the fuel return line from the primer bulb. Then, use snippers or scissors to cut the return fuel line close to the fuel tank. Remove the fuel cap and the compression fitting. Finally, use a utility knife to separate the old fuel line from the plastic fitting.
You will need a good pair of hemostats, snippers or scissors, and a utility knife. You may also find long needle-nose pliers, a flat-head screwdriver, and a thin piece of wire useful.
Ensure you buy a fuel line that is long enough and the correct size for your model of chainsaw. The line must fit very snugly through the hole in the tank.
Thread the angled end of the new fuel line through the mounting hole on the fuel tank. Pull the new line through the mouth of the tank, being careful not to pull it out of the mounting hole. Square off the end of the line and install the plastic fitting. Secure the new fuel line and fitting to the tank using hemostats.
