Fuel Line

Watch video on youtube for chain saw fuel line and filter repair. Made it easy!

1. Removed the fuel tank and carb.
2. Rebuild the carb.
3. Removed what was left of the fuel line.
3. Installed new fuel line, which was very difficult.
4. line fits thru a hole on the fuel tank. This required the line to be forced thru a smaller hole than the OD of the fuel line. I ended up putting silicone grease on the OD of the line and pushing the line thru the hole using a small punch.
5. Once I got enough line thru the hole and out thru the fuel tank cap side, I was able to pull it from that side until I had line that was not pushed thru using the punch.
6. I cut the line close to the fuel cap side of the tank and installed the fuel filter onto the line. The fuel filter just drops into the tank.
7. I then reinstalled the tank and carb.
8. Once all the hardware is reinstalled, I measured and cut the fuel line to fit onto the carb.
9. This may sound easy, but it was not. The weed eater runs great now (its almost 20 years old).

- Removed top cover (to access carb area and allow side panel removal)

- Removed side cover where primer bulb is located

- Remove old snap in primer bulb (without disconnecting fuel lines)

- Cut and replace the 2 fuel lines one at a time (mine were hard and brittle from old fuel)

- The new bulb has 2 fuel ports, one is longer than the other which matched the old bulb.

- Installation instructions said to double check the direction of the fuel flow (the bulb sucks fuel through the carb, so the inlet side is connected to the carb and the outlet side goes back to the fuel tank).

- Snap the new bulb into place on the side panel

- Attach the side panel

- Attach the top panel

I have 1996 poulan 2550 super clean 18" chain saw , last used it in 2005,pulled out of storage to use and primer bulb was cracked, so I purchased new fuel lines,bulb,air and fuel filter. The repair went fairly easy, 3 screws to remove air filter top cover, 4 screws side cover with pull start, 2 nuts that retain air plenum,and carburetor, disconect throttle linkage with needlenose pliers,move air plenum with throttle cable to left side, then able to slide carb and choke lever back to gain access to tank inlet(left side) and return(right side). Removed old line stuck in inlet and return with small diameter philips screw driver,they just tapped through, fished out old fuel filter and bits of old line with hemo stats, new fuel lines had diagonal cut at end which I put white lube on outside of hose at end and fed through holes, large dia is return,small dia is feed,enough to reach in with hemo stats and tug through( hardest part of repair).The next hardest part was figuring out lines, I found a youtube that ereplacementparts did in 2009 that helped me determine that starting from bulb center large dia to return in tank,small dia from bulb goes to top rh side of carb,bottom left side of carb to small dia inlet side of tank, pulled small line from tank and put fuel filter on, lays flat on bottom of tank.I slid the carb back down on studs making sure fuel lines are clear , move air plenum up to carb,then install throttle linkage with needle nose pliers,push air plenum on studs and thread nuts on and tighten evenly , put dab of 30w non detergent oil on foam air cleaner worked in, plulled spark plug , was clean and in good condition. replaced starter housing and top cover, repair time was approximately 1 hour, including coffee break, everything worked fine. Don :)

This process looks long but I assure you it is super easy and takes no time at all. If this is your first time taking a fuel system apart take pictures or use a IPB so you do not have to rely on memory for reassembly.

1. First I drained and disposed of all the old fuel.

2. Then I removed the fuel filter from the intake hose in the fuel tank with needle nose pliers. Once the fuel filter was removed then I remove the return line fuel assembly pickup (fancy name for little plastic insert) with needle nose pliers.

3. After both the fuel filter and fuel assembly pickup was remove then I removed the gas tank carefully, thus not to tear the fuel lines. The fuel tank is held on with two star screws so you would need the proper star screw driver or ratchet attachment.

4. Next I removed the hoses from the carburetor also careful not to tear the fuel lines. The reason for such care is because I used the old hoses to determine the size of the new hoses. Now for the carburetor.

5. I removed the air filter and air filter cover there are two Allen screws that hold on the carburetor. Using a the proper Allen key I remove both screws. Be careful not to tear any gaskets when removing. Also the throttle cable to attached to the carburetor it is easy to remove just angle the L properly and it slides right out.

Now that the carburetor is removed assess the situation. In my case I took the carburetor apart to see if I could clean it before I ordered a new carburetor but this was beyond cleaning. If you have never taken a carburetor apart proceed with caution and read a different repair guide.

Most of the parts where rusted and gummed and for 25 bucks I simple decided to order a new one. Also since I had the fuel take off I cleaned it and ordered new hoses, fuel filter, and a new fuel tank cap. I only ordered a new cap because the other one was cracked.

6. Once the parts arrived I began by cutting the new fuel hoses. I used the old hoses to determine the size. NOTE: Cut the new pieces a little longer than the old ones because the hardest part of the project is putting the new hoses into the fuel tank. And unless you are really good you will tare up the ends a bit and will need to be cut off. Plus you will need to cut the new ones at an angle so you will need to cut that flat as well.

7. After the cut is made, cut the end of the hoses at a sharp angle thus to be able to put the tip of the hose through the holes int he fuel tank. I recommend using a little lube on the outside of the hoses as well just so they slide easier. In my case I used a little 2-cycle oil because I knew it would not contaminate the line or the gas in the fuel tank. Once the hoses where just barely through the hole I grabbed the end of the hoses with needle nose pliers and pulled the desired length. On the intake hose I cut the end flush and attached the new fuel filter then put it back into the fuel tank. Also cut and attached the return line fuel assembly pickup to the return line then pulled it up to the top of the fuel tank.

8. Before I attached the tank I put the new carburetor on the same way I took it off making sure to attach the throttle cable as I went. When the screws where in line I tightened them down snug. Do not over tighten.

9. Now I attached fuel tank in same manner not to over tighten the screws.

10. Finally I attached the fuel lines to the carburetor filled the fuel tank with good 2 cycle and closes the fuel tank with my new fuel cap. Attached the air filter and air filter cover and we where good to go.

Primed the carburetor, put it full choke, cranked a could of times went into half choke. It fired right up, went to no choke and gave it full throttle and she purred like a kitten. Okay it is a line trimmer she roared like a lion but either way it is working great.

To get the new fuel line in the tank you must bevel the end, about an inch, with a very sharp knife. Push this end through the hole in the gas tank then reach in with a long, long nose plier and pull the end of the fuel line slightly out of the filler neck, cut off the bevel, install the filter then pull it back so the fuel filter rests on the tank bottom.

Two lines going into tank.
Take pictures before you start on which lines go where.
Unscrewed tank and was putting back on in 15 minutes.
Hardest part was getting new line back into tank.
Easy thing was line was already pre cut at angle.

Remove the fuel from the fuel tank. Bend a hook in a length of wire and fish the fuel filter out of the fuel tank. Remove the fuel line from the primer bulb. Then remove the fuel line from the fuel tank. Install the new fuel line on the primer bulb. Then on the other end of the fuel line cut it diagonally, then and put some oil on the end of it and press it into the tank. If you have some hemostats or long needle nose pliers, take hold of the hose that's inside the tank and pull it out of the tank. Measure how much you will need to have the fuel filter sit properly in the tank , then cut it off straight and place the hose on the fuel filter. Put the filter in the tank. Put the fuel in the tank, and you should be ready to do some cutting.

The fuel system disintegrates from the ethanol in gasoline, so I ordered the necessary parts; fuel filter and fuel line, purge line (different size), and a primer bulb, if one is needed.. If the primer bulb is tore, cracked, or makes a whistling sound, replace it first. Get a diagram online if your fuel lines are in pieces, but if they are intact, remove the fuel line from the back of the primer assembly, slowly pull the fuel filter and fuel line out through the fuel fill port. Cut your new fuel line's end at a diagonal, so that you can insert it through the hole in the gas tank. Slowly push enough through until you can grab it from the fuel fill port. Cut off this diagonal piece so that the end is once again square, and install your new fuel filter. Pull the fuel line back enough so the fuel filter is at an appropriate pickup point, I.e., close to the bottom of the tank while running. Cut the fuel line so that it just connects with the primer assembly. Remove the purge line from the primer assembly and use it to cut a new purge line slightly longer, with a diagonal cut on one end. Feed the diagonal end through the tank wall, and connect the other end to the primer assembly. I was able to do my 2 machines from one fuel line and purge line kit.

1) Removed top cover
2) Removed Spark Plug
3) Removed Side Cover
4) Removed Helper Handle
5) Drained Fuel Tank
6) Recover Fuel Filter
7) Took Pictures of Carburetor and Fuel Line Routing
8) Removed Fuel Lines
9) Removed Primer Bulb
10) Removed Carburetor
11) Fish new Lines into Fuel Tank, cut to size
Re-install parts