How to Replace Fuel Lines Poulan Chainsaw

Do you own a Poulan Pro chainsaw, and you’re looking to replace the fuel lines but don’t know how? If yes, then this is definitely the right place.

Replacing fuel lines, Poulan chainsaw is pretty easy if you know the right way to do it. The right method to replace fuel lines on a Poulan chainsaw involves collecting a new fuel line, a screwdriver, and a pair of pliers. Then, remove the old fuel line from the fuel tank of your chainsaw. After that, disconnect the old fuel line from the chainsaw carburetor. Then, you need to connect the new fuel line to the fuel tank and the chainsaw carburetor.

Lastly, you need to use the pliers for tightening the connections and a screwdriver for securing the new fuel line in place. Remember, whenever you are dealing with a chainsaw, you must wear proper safety gear and follow relevant safety protocols.

In this article, you will get to know all about fuel lines in chainsaws, how to replace fuel lines Poulan chainsaw, how do fuel lines work, how to replace gas tubing on a Poulan chainsaw, and more. Continue reading to get all the answers that you are looking for.

Fuel Lines on Poulan Chainsaws

Fuel lines eventually get brittle and end up cracking over time. If you own a Poulan Pro chainsaw, you’ll need to replace the fuel lines on your chainsaw at some point. There are various fuel lines found on the small engines of the chainsaw. There will be a line that carries fuel from the tank to the carburetor, with a second line that passes excess power from the carburetor to the fuel tank. 

Chainsaw fuel lines are essentially clear plastic tubing. When it is time to replace the chainsaw fuel lines, it’ll be important that you’re cutting new tubes to the proper length. Use needle-nose pliers for removing the tubes from the carburetor, and then pull them from the tank. When you’re removing the fuel line that feeds fuel to the carburetor, a small cylindrical fuel filter would pop off of the tube. You must hold the lengths of the original tubing against the replacement tubing and then cut the new tubes to the same lengths for ensuring you get a proper fit.

How Do Fuel Lines Work

Whether you are a professional lumberjack or a homeowner with a backyard, you should always check the fuel lines of your chainsaw. Alongside the two fuel lines mentioned above, there are many models that come with a small purge bulb, connecting the third line between the bulb and the carburetor.

Some models also have a small fuel tank vent and another fuel line that is connected to the tank. When you’re examining the fuel lines supplying gas to the engine and find them faulty, you’ll be able to replace them yourself instead of taking the machine for repair.

When it comes to repairing, even if it isn’t convenient to replace damaged or cracked fuel lines on the chainsaw, it’ll be an easy task that even a beginner can perform with proper guidance.

How to Replace Fuel Lines Poulan Chainsaw

Sometimes, the chainsaw fuel lines carrying fuel from the tank to the carburetor could crimp, clog, or crack over time. Damaged fuel lines will restrict fuel flow while preventing the engine from starting. If the chainsaw wouldn’t start, you should clear clogs and then check the fuel lines for any crimps or cracks. Remember to replace damaged or crimped fuel lines with manufacturer-approved chainsaw parts. Here are the steps you need to follow to replace the fuel lines on your Poulan Pro chainsaw –

1. Separate the spark plug and empty the fuel

First, you need to separate the spark wire from the spark plug that is blocking the accidental ignition of your chainsaw during the fuel line change. Now, you’ll be able to empty the fuel from the gas tank into gas and then secure it away from where you’re working for replacement after repair.

After this, you should open the power from the gas tank into gas and then secure it away from where you’re working for replacement after repair.

2. Remove the primer bulb

Now, you will need to replace the screws that are holding the outer housing of your chainsaw in place such that you can open the carburetor gas tank and primer bulb.

Remember to place the screw and housing aside for changing at the end of the repair. You’ll need to have easy access to the tubes leading to it, which means it’ll be time to remove the primer bulb.

3. Remove the thinner fuel line and change the old piping

You should take out the thinner tube linking the primer bulb to the carburetor by carrying it out using your fingers. It is imperative for the new tube to have the same lengths, so you should grab it relative to the new tubing that has the same height. After that, change the old piping it connecting it to the primer bulb and carburetor.

4. Replace the thicker fuel line

Now, you’ll need to replace the thicker tube connecting the primer bulb to the fuel tank by removing it with water. Grasp it in new tubing that has the same diameter, and then cut it into new tubes having the same length. Remove the old fuel line with a new one. You should connect it to the primer bulb and then insert it into the fuel tank.

5. Pop the fuel filter off and connect a new one

Detach the screws that are holding the carburetor in place to replace it such that you can reach the fuel lines that are working under it. You should enlarge it into the fuel tank and then replace the fuel line.

Pop off the fuel filter and then connect the new fuel filter at the end of the tubing. You must place the fuel filter and tubing in the fuel tank for connecting to the other end of the carburetor. Further, you should also detach it by changing the screws that you’ve removed.

6. Put the cover back on the chainsaw

Finally, you should fit the screw responsible for holding the primer bulb in place. Put back the cover on your chainsaw and reset the screws that hold it into place.

How to Replace Fuel Lines on Any Chainsaw in 3 Simple Steps

1. The disassembling

First, you need to drill the fuel from your chainsaw and remove the top cover. You will have to remove the air filter, air filter cover, and air filter base. You should also remove the throttle linkage. The trigger should be pulled away from the trigger.

After that, it’ll be the turn of the carburetor, then the two fuel lines will go into the carburetor. One line will be from the tank, while the other line will go to the primer bulb. After that, you should be removing the returning line from the primer bulb. You will find a fitting on the end of the return fuel line in the fuel tank. You should cut the line first and get the fuel cap off.

2. Replacing the chainsaw with new fuel lines

Once you have got the fuel cap off, you should use hemostats for pulling the fitting and fuel line from the tank. Remove the fuel line from the fitting in the tank, and then it’ll be time to cut a new fuel line.

The old piece of the line should be used as a guide. You must add a bit of extra line so that you can make up for the line that you cut off before. Now, you need to place the new piece of fuel line into the fuel tank’s opening.

Use hemostats and then hold and pull the line out via the tank opening. Using hemostats, you should pull the cable until the fitting comes in contact with the underside of the tank, and it’ll be ready to function. Now, reconnect the return line to the primer bulb.

3. Reinstall the fuel

Reinstall the fuel lines on your carburetor, namely, the incoming line to the bottom of the carburetor and the line to the primer bulb. You should install the remaining things that you removed at the onset.

First, install the carburetor and then install the throttle linkage. Pull the trigger and slide linkage of the chainsaw back into place. After that, you should be reinstalling the air filter base. Then, install the air filter and the air filter cover. Lastly, you need to replace the top cover.

Tips to Remember When Replacing Fuel Lines

Use proper tools for this job as it will make fuel line replacement easier. Once you are ready to insert the tubing into the gas tank, it could be tricky to advance the tubing fully into the tank such that it reaches the bottom of the container. Once you’ve got a small piece of tubing emerging into the hole of the tank, you should use a pair of bent needle-nose pliers to grasp the tubing and then pull it through. Alternatively, a pair of hemostats will be another tool that will allow you to carry out the same function. Further, you should also include a pair of scissors in your toolkit such that you can cut the tubing. 

When you are making changes to your chainsaw, you may find that it is difficult to feed new plastic tubing into the plastic tank. Instead of looking to force the issue, you should spray a bit of lubricant onto the tube before insertion to make this process easier. Cut the tip of the fuel line, fitting into the tank on a diagonal angle. This will allow the fuel to feed into the tub much more easily while also helping with insertion.

How to Fix Damaged Gas Tubing and Hoses on a Poulan Pro Chainsaw

The fuel supply hoses on a Poulan Pro chainsaw carry fuel from the fuel tank to the carburetor and purge bulb. The purge bulb will prime the carburetor for easier starting by injecting more fuel into the carburetor. The return fuel hose will return the unused purge bulb fuel to the chainsaw’s fuel tank. The flexible fuel hoses could harden and become brittle when they are exposed to oil, fuel, and engine heat and need to be replaced to prevent flash fire or fuel spillage.

1. Drain the fuel tank

First, you need to drain the fuel tank. To achieve that, you should pull the carburetor fuel supply hose and filter from the fuel tank. Now, pull the fuel filter housing nipple from the end of the carburetor fuel supply hose.

2. Unscrew the retaining plugs

Now, you should unscrew the retaining screws and then remove the engine cylinder shroud from the top of the chainsaw engine. You should also unscrew the retaining screws and then lift the starter housing from the engine chassis on your chainsaw’s left side from the operator’s position.

3. Remove the carburetor and air filter housing

After that, you should lift the air filter from the air housing that is located under the starter housing. Remove the two carburetor mounting nuts that have a socket wrench. Unscrew the two outer retaining screws before removing the air filter that is housing the top chainsaw engine and carburetor.

4. Pull out the purge bulb

Unscrew the purge bulb that is retaining screws from the engine chassis. Now, you should pull the purge bulb out of the chassis.

5. Remove the different fuel return hoses

Now, you should be removing the large fuel return hose from the housing nipple of the backside purge bulb. Pull out the purge bulb return fuel hose from the fuel return hose inlet that’s present on the top and right side of the fuel tank. After that, unclip the return fuel hose from the retaining clip of the carburetor adapter plate fuel hose. Finally, you should pull the return fuel hose that is under the carburetor and is free from the engine chassis.

You should also pull the purge bulb fuel supply hose from your chainsaw’s carburetor’s lower fuel inlet fitting.

After that, pull out the carburetor fuel supply hose from the supply inlet fitting that’s located on the top-right side of the carburetor on AV models and the top-left side of the carb on non-AC chainsaw modes. After that, you should unclip the fuel supply hose via the retaining clip. Now, you should pull the supply hose from the inlet fitting present on the top-left side of the fuel tank.

6. Push the fuel supply and housing

Now, you should be pushing the new carburetor fuel supply hose into the hose inlet present on the top-left side of the fuel tank. Pull up the hose from inside the fuel tank using needle-nosed pliers for grasping the small hose. You should be pushing the end of the fuel filter housing nipple into the fuel supply hose while pushing the fuel filter housing into the chainsaw’s fuel tank.

7. Route the new carburetor fuel supply hose

Now, you need to route the new carburetor fuel supply hose under the chainsaw carburetor and then feed it into the fuel inlet that is fitting on the carburetor’s top. After that, clip the hose into the chainsaw’s adapter plate fuel hose retaining clip.

8. Push the new purge bulb

Here, you will need to push the new purge bulb return fuel hose right into the return hose inlet located on the top-right side of the fuel tank. Push the hose that is under the carburetor and then clip it into the fuel hose retaining clip. Lastly, push the hose end into the large nipple present on the purge bulb housing.

9. Push purge bulb fuel supply hose

Now, you need to push the new purge bulb fuel supply into the inlet fitting located on the lower-left side of the carburetor. After that, push the hose end onto the small nipple present on the purge bulb housing. Lastly, you should push the purge bulb housing into the chassis of your chainsaw and then tighten the retaining screw using a screwdriver.

10. Check your chainsaw for fuel hose operation

Now, you should assemble the chainsaw starter housing, air filter housing, and cylinder cover again. Fill in the fuel tank with fresh fuel. Lastly, you should start and stop the chainsaw numerous times to check for proper fuel hose operation.

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