How to Replace a Chainsaw Fuel Line
Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.
Step 1: Drain the fuel tank
In a well-ventilated area, remove the fuel cap and empty the fuel tank into an approved storage container.
Step 2: Remove the cylinder shield
Using an Allen wrench, remove the screws that hold the cylinder shield to the engine. Lift off the shield.
Step 3: Disconnect the spark plug wire and remove the air filter
Disconnect the wire from the spark plug. Pull the cover off the air filter housing and remove the filter.
Step 4: Remove the fuel filter
Straighten a piece of coat hanger and bend a hook on the end. Feed it through the mouth of the tank and fish out the white cylindrical fuel filter. Cut the fuel line to remove the filter.
Step 5: Remove the carburetor mounting nuts
Using a 7/16" socket driver, remove the two mounting nuts that secure the carburetor to the engine.
Step 6: Remove the air filter housing
Pull the air filter housing off the carburetor.
Step 7: Remove the carburetor
Pull the carburetor from the engine block, sliding it along the mounting studs. Be careful not to bend the throttle linkage or damage the gas lines.
Tip: For accurate reassembly, take digital photos of the throttle linkage on the carburetor and the gas line connections.
Step 8: Disconnect the fuel lines from the carburetor and primer bulb
Pull the fuel lines off the carburetor and primer bulb, using needle-nose pliers.
Tip: With some chainsaw models you’ll have to remove the screws from the primer bulb to detach the fuel lines.
Step 9: Remove the fuel lines from the tank
Use needle-nose pliers to pull the fuel lines out of the gas tank.
Step 10: Push the new fuel lines into the tank.
Use a pair of scissors to cut the new fuel lines at an angle to thread them into the tank. Push the large line about 1 inch into the tank. Push the small line far enough into the tank so that it can be grabbed through the mouth of the tank with needle-nose pliers.
Tip: To ease threading, lubricate the fuel lines with a drop of oil.
Step 11: Install the filter
Pull the small line out the mouth of the tank. Cut the end square and install the fuel filter. Pull the line back in so the filter rests on the bottom of the tank.
Trim the fuel lines and connect them to the carburetor.
Step 12: Reinstall the carburetor
Slip the carburetor onto the mounting studs and push it into place. Position the air filter housing on the protruding studs.
Replace the mounting nuts and tighten them to seal the gasket between the engine and the carburetor.
Tip: Avoid crimping the fuel lines when re-installing the carburetor.
Step 13: Reinstall the air filter cover and connect the spark plug
Position the air filter in the housing and replace the cover. Reattach the spark plug wire.
Step 14: Reinstall the cylinder shield
Reinstall the cylinder shield on the chainsaw. Refill the fuel tank.