Purge Line

- 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

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.

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.

I disassembled the exterior of the saw.
I removed the existing fuel line.
I reran the fuel line from the tank to the carburetor.
I reassembled the saw.
The most difficult part was removing the old filter from the gas tank.
To remove the filter I made a hook out of some wire, and fished the line and filter out
I purposely took my time since I am not a mechanic

Remove the carburetor and replaced all gaskets, fuel pump diaphragm and regulator diaphragm. Reseated bulb and replaced the gaskets which mate the carburetor to the engine's intake manifold. Once completed, I tightened all the bolts on the crankcase and engine head, replaced and gapped the spark plug. The unit started on the second pull and is running great.

A quick note about the Walbro rebuild kit and the original parts in the carburetor. The fuel pump, for these carbs, in the original was a piece of blue plastic/mylar(?) that was solid. The replacement fuel pump looked like a mesh screen. That had me confused, for a bit. I did not realize that the replacement parts would look so different from the originals. That said, I should laugh at myself because this unit was made in 1996 and this is the first time it's been rebuilt. Things have changed, a bit, since them, obviously. LOL.

This was a quick, and easy job. If you can use a screwdriver you can do this work.

Removed gas tank from chainsaw to remove filter and all pieces of broken gas line, installed new fuel line to filter, then feed filter into tank , reinstalled tank , then routed fuel line thru boot and into carb.

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 Remove fuel tank and carburetor
2 Insert lines into tank and attach filter
3 Reattach tank

4 Insert lines onto carburetor
5 Reattach carburetor.( not an easy task)
The smaller intake line has an undersized I.D. which required heated stretching in order to slip over the carburetor inlet pipe.

Hardest part getting the fuel line and the purge line through the tiny hole, in gas tank? I used a piece of wire I attached to the end of the fuel line and fed it through.

1. Removed cover from right side along with chain and bar.
2. Removed handle and carburetor cover.
3. Disconnection what little line was left noting routing of the fuel line.
4. Connect new line to carburetor and route line along handle to the fuel tank. Make sure you leave enough fuel line to reach the bottom of the tank.
5. Install the tapered end of the line into the tank until you have enough line installed to reach the bottom.
6. Fill the tank with gas and oil mixture.
7. Prime the carburetor by pouring a small amount of gas into the carburetor. With the switch in run pull the rope until it fires. You may need to prom the saw several times to get the air out and enough gas into the line to keep it running.
8. Reinstall the bar chain and covers. Replace the air cleaner and clean or replace the spark plug if needed.