How to Replace Leaf Blower Fuel Lines

 

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This step-by-step repair guide shows how to remove and replace leaf blower fuel lines. Fuel lines can clog, crimp or crack. Damaged fuel lines restrict gas flow and prevent the engine from starting and running. Clear clogs and check for crimps or cracks in the fuel lines. Replace any cracked or damaged fuel lines with a manufacturer-approved replacement part.

This basic procedure works for Craftsman, MTD, Husqvarna, Poulan, Weed Eater and Troybilt leaf blowers.

If the engine won't start after replacing leaky fuel lines, you may need to rebuild the carburetor, following the instructions in How to Rebuild a Leaf Blower Carburetor.

Repair difficulty:
     
Time required:

Less than 60 min.

Parts Required

  • Fuel lines

For manuals, repair guides, and specific part recommendations, enter your model number.

Tools Required

  • Torx screwdriver
  • Needle nose plier
  • Approved fuel container
  • Scissors
  • Work gloves
  • Paper towels or shop rags

Before you begin

Wear work gloves to protect your hands.

Instructions

 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 from the fuel tank into an approved storage container. 

Step 2: Disconnect the spark plug wire

To ensure that the leaf blower can’t start, disconnect the wire from the spark plug.

Step 3: Remove the blower tube

Loosen the thumb screw on the front of the housing and pull the blower tube off.

Step 4: Remove the air filter cover

Remove the screws from the air filter cover and then remove the air filter cover.

Step 5: Remove the carburetor

Remove the carburetor mounting screws.

Pull out the air box and release it from the carburetor throttle and choke levers.

Note the configuration of the small and large fuel lines on the carburetor so you can reconnect them correctly later and then remove the fuel lines from the carburetor.

Remove the carburetor from the engine.

Remove the screws from the carburetor adapter.

Pull the carburetor adapter and air dam off of the engine.

Step 6: Remove the fuel tank

Remove the screws from the front of the muffler guard cover and pull the guard cover off the muffler.

Remove the blower tube thumb screw from the front of the housing.

Remove the screws from the right side of the housing and pull the left side of the housing off the blower. The fan cover and handle come off with the housing.

Remove the fuel tank from the housing.

 

 Tip: Note the configuration of the spring on the fan cover before pulling the blower housing apart.

Step 7: Pull the fuel lines out of the tank

The end of the small fuel line is connected to the fuel filter inside the tank. Use needle-nose pliers to fish the fuel filter out of the mouth of the tank. Remove the fuel filter from the end of the small fuel line.

Pull the small fuel line out of the tank through the mounting hole. 

Push the large fuel line into the tank through the mounting hole and pull it out of the mouth of the tank. 

 

Step 8: Install the large fuel line

Cut one end of the large fuel line at an angle.  

Push the angled end into the tank through the mounting hole far enough that you can grab the end through the mouth opening with needle-nose pliers. Cut the angled end of the large fuel line square and install the grommet on the end.

Tug the opposite end of the large fuel line until the grommet touches the side of the tank.

Cut the large fuel line to the same length as the original large fuel line.

 

 Tip: To ease threading, lubricate the fuel lines with a drop of oil.

Step 9: Install the small fuel line

Cut one end of the small fuel line at an angle.

Push the angled end into the tank through the mounting hole far enough that you can grab the end through the mouth opening with needle-nose pliers Pull the small line out the mouth of the tank. Cut the angled end of the fuel line square and attach the fuel filter. 

Push the small line back into the tank through the mouth opening. Tug the other end of the small fuel until the filter rests on the bottom of the tank.

Cut the small fuel line to the same length as the original small fuel line.

Step 10: Reinstall the left side of the housing

Position the left side of the housing near the leaf blower and thread the fuel lines through the hole in the housing near the carburetor.

Position the handle properly and push the housing back together, making sure the eyelet for the starter pull cord is properly positioned.

Insert the thumb screw in the housing at the front of the blower and rotate the screw just until it catches the nut; don’t tighten it yet.

Loosely install two other housing screws to keep the housing in place while you install the fan cover.

Pry the tab on the fan cover spring out until it is in the loaded position. Snap the fan cover into the housing while holding the spring in the loaded position.

Insert all of the housing screws and tighten them firmly. 

Reinstall the guard cover on the muffler.

Reinstall the fuel cap.

 

Step 11: Reinstall the carburetor

Push the fuel lines onto the proper connections on the carburetor.
Insert the carburetor into the air box with the throttle and choke levers positioned properly.

Position the carburetor on the side of the engine and reinstall the mounting screws.

Position the air filter cover over the carburetor and secure it with the mounting screws.

Step 12: Reinstall the blower tube

Push the blower tube back on the front of the housing and tighten the thumb screw.

Step 13: Connect the spark plug

Reattach the spark plug wire.