How to Replace Fuel Lines on a Poulan Chainsaw? A 2022 Guide

replacing fuel lines on a Poulan chainsawReplacing Poulan chainsaw fuel lines is not a difficult task but it does require some tricky steps. With the right tools and proper know-how, this can be done in a matter of an hour or less.

Whether it is replacing the new lines or attaching the pulled-free ones, this article provides a comprehensive guide on reinserting the tubes back in the tank and how to replace the fuel lines on a Poulan chainsaw.

Although the guide is specific to Poulan gas-powered chainsaws, the same procedure can be followed for Craftsman, McCulloch, Troybilt, Husqvarna, and MTD chainsaws as well.

Let me now get to the chase without any further ado:

How to Replace the Fuel Lines on the Poulan Chainsaw in 2022?

Fuel lines are responsible for carrying fuel to the carburetor in gas-powered chainsaws. With time they can experience

  • Clogging
  • Crimpling
  • Breaking
  • Can be pulled free from the tank

All these scenarios restrict the fuel flow and prevent the engine from starting. The fuel lines are as follows

  • Fuel filter line
  • Primer suction line
  • Fuel return line (smaller diameter)

The size of the replacement fuel lines should match the original ones. So when you take out the old ones, cut the new ones to the right size before cutting the filter off.

Before you get your hands dirty with the work

  • Make sure the chainsaw is off and cooled down
  • Make sure to do this in a well-ventilated place

To get better understanding, check the fuel line diagram for the Poulan chainsaw below:

Poulan chainsaw fuel line diagram
Credits: iFixit

Steps to Follow for Fuel Replacement in Poulan Chainsaw

Step 01: Gather the equipment

To avoid unnecessary running around and get it all done quickly, gather the following tools

  • Allen wrench
  • Socket driver
  • Needle-nose pliers
  • Approved fuel container
  • Scissors
  • Work gloves
  • Wire coat-hanger
  • Towel or rag

Step 02: Drain the fuel tank

Remove the fuel cap.

Empty the tank in an approved container.

Step 03: Remove the cylinder shield

Use an Allen wrench to unscrew the screws holding the cylinder shield.

Lift the shield off.

Step 04: disconnect the spark plug wire

Locate the spark plug. It is either behind or above the air filter.

Gently twist and remove the wire from the spark plug.

Step 05: Remove the air filter

Remove the filter from its housing.

Step 06: Remove the carburetor

Remove the nuts that secure the carburetor using the socket driver.

Pull the air filter housing above the carburetor.

Remove the choke lever.

Remove the throttle linkage by pulling the trigger to get to the end of the linkage and pull it away from the trigger.

Carefully pull the carburetor off the mounting studs.

Step 07: Disconnect the fuel line

Use a needle-nose plier to pull the lines off the carburetor.

In some battery saws, you may have to remove the screws before removing the fuel line from the primer bulb.

Again using pliers take all of them out of the fuel tank.

Step 08: Remove the fuel filter

Straighten the hanger and bend a hook on one side.

Through the mouth of the tank take out the cylindrical fuel filter.

Cut the new filter fuel line to the size of the old one.

Remove the filter by cutting the fuel lines.

Step 09: Installation of New Fuel Lines

The size of the new fuel lines should match the old ones.

  • Cut the other fuel lines to the size of the old ones.
  • Make a small cut at an angle on the new thicker fuel line.
  • Lubricate the lines with a drop of oil to make the whole process easy.
  • Push the fuel filter line into the tank enough so it can be pulled out on the other side from the tank opening.
  • Take it out from the opening but not too much.
  • Make a square cut on that end and install the fuel filter.
  • Now pull the line back up from the other side using pliers till the filter resets on the bottom of the tank.
  • Connect the primer suction line to the primer.
  • Connect the fuel return line to the primer and place the other side in the tank.

Step 10: Reinstallations and Reattachments

Once all the lines are connected to their respective points

Reconnect the carburetor

  • Reconnect the throttle linkage.
  • Reconnect the choke lever
  • Reinstall the air filter and its housing.
  • Reattach the spark plug wire.
  • Reinstall the shield.

Have a look at this video tutorial for proper fuel line replacement:

Poulan Chainsaw Fuel Line Repair Kit

Different marketplaces offer multiple repair kits at different price points. These kits contain some or all of the following

  • Replacement lines
  • Air filter
  • Spark plug
  • Carburetor
  • Carburetor mounting gasket
  • Carburetor brush
  • Primer bulb
  • Fuel line hose

And much more. Each kit offers a different set of things. You can get which suits your needs the best.

Frequently Asked Questions

How to perform Poulan Pro 42cc fuel line replacement?

This article covers a comprehensive guide on how to replace fuel lines for Craftsman, McCulloch, Troybilt, Husqvarna MTD, and Poulan including Poulan Pro 42cc. Check out the steps mentioned below to replace fuel lines on your Poulan Pro 42cc gas chainsaw.

How do you replace the fuel line on a Poulan chainsaw?

  • Drain the fuel tank.
  • Take out the spark plug wire, air filter, and housing.
  • Remove the carburetor.
  • Disconnect the old lines using needle-nose pliers.
  • Put the new line in the tank on one side and take it out from its opening on the other side.
  • Place the fuel filter.
  • Pull out the line from the tank till the filter sets its place.
  • Install the lines back on the carburetor and primer bulb.
  • Reinstall the carburetor.
  • Reattach the spark plug wire and air filter along with its housing.
  • Put the shield back on.

For a detailed step-by-step guide check this article.

Where do all fuel lines go on a Poulan chainsaw?

There are three fuel lines in Poulan Chainsaw

  • Fuel filter line: one side is connected to the fuel filter and the other to the carburetor.
  • Primer suction line: one side is connected to the carburetor and the other to the primer bulb.
  • Fuel return line: it is connected to the primer bulb on one side and the other side stays in the tank.

Which fuel lines go to the primer bulb?

The clear transparent one goes from the carburetor to the primer bulb. It is also called a primer suction line and has a thick diameter. Another one with a small diameter went from the primer bulb to the tank.

Why does my Poulan chainsaw die when I give it gas?

Your Poulan chainsaw could die upon giving gas due to one or more of the following reasons

  • Clogged air filter
  • Clogged fuel filter
  • Stale gasoline
  • Damaged or crimped fuel lines
  • Damaged spark plug and/or spark plug wire

To avoid issues with the ignition, read this guide on How to Start a Poulan Chainsaw

How to get fuel lines into chainsaw tanks?

  • Unplug the spark plug wire.
  • Remove the air filter and its housing.
  • Remove the carburetor.
  • Remove the fuel lines.
  • Remove the fuel tank cap.

This provides the 2-way pathway to the tank.

Final Takeaways: How to Replace Fuel Lines on Poulan Chainsaw?

Fuel line replacement is part of chainsaw maintenance. These lines are responsible for the flow of fuel from the tank to the carburetor. With time the lines clog, crimple, or can break, and when this happens they need to be replaced. This limits the fuel’s flow, which makes it difficult for the engine to start.

Inserting the tubes seems straightforward, but this task has some tricky steps. With all the necessary tools gathered in a ventilated space, this can be achieved within an hour.


Richard McMann

Richard lives out in the wild with his other half, Diana Richard. He tests chainsaws based on his personal experience and loves to share their nitty gritty details with his audience. Although Richard does focus on other home improvement tools, his focus remains on cutting fallen trees or maintaining his backyard via chainsaw tools. He pledges to come up with new knowledge about chainsaws every once in a while. Explore Details About Richard