Replacing a cracked or deteriorated fuel line on your Poulan chainsaw restores proper fuel delivery and prevents starting/running issues. Follow this detailed 300-word guide to complete the repair in under 30 minutes.
Tools & Parts Needed
✔ Replacement fuel line (measure old line or check manual for diameter/length)
✔ Needle-nose pliers
✔ Small flathead screwjack
✔ Safety gloves & glasses
✔ Carburetor cleaner (optional)
✔ Fresh fuel mix (for testing)
Step 1: Safety Preparation
- Disconnect spark plug wire
- Drain all fuel from tank
- Clean exterior to prevent debris entry
Step 2: Access the Fuel System
- Remove air filter cover and filter
- Detach carburetor cover screws
- Carefully lift carburetor assembly (note gasket position)
Step 3: Remove Old Fuel Line
- Pinch and pull fuel line from tank nipple
- Use pliers to extract tank grommet if stuck
- Disconnect opposite end from carburetor inlet
Pro Tip: Take a photo before disassembly for reference.
Step 4: Install New Fuel Line
- Insert new line through tank grommet (lubricate with oil if tight)
- Ensure 1/4″ of line extends into fuel tank
- Connect to carburetor inlet (listen for “click” of secure fit)
Step 5: Reassembly & Testing
- Reattach carburetor with original gasket
- Reinstall air filter assembly
- Add fresh fuel mix (50:1 ratio)
- Prime bulb (if equipped) and test start
Troubleshooting Tips
🔧 Leaks at connections? Double-check line seating and replace grommets
🔧 Fuel not reaching carb? Verify line isn’t kinked and primer bulb functions
🔧 Hard starting after repair? Check for air leaks at connections
Preventative Maintenance
- Replace fuel lines every 2 years or when stiff/cracked
- Use ethanol-free fuel to reduce deterioration
- Store with empty tank when not in use
Note: Poulan Pro models may have slight variations – always consult your manual for model-specific diagrams. Most homeowner-grade Poulan saws use 3/32″ ID fuel line available at any small engine shop.
