Fuel Line Fitting

Removed the top cover (T25 torx), and side cover (T25 torx) with recoil starter. Drained all fuel, and removed all pieces of fuel old fuel line and the weighted filter from inside the tank by shaking out and the (long forceps). A spot headlamp makes it easier to see inside the tank for much of the procedure. Remove the foam filter to find the two 8mm nuts and remove the air filter housing and carburetor (nut driver, 8mm socket) the choke lever slides out of its slot with some wiggling and moving the carb back off the mounting studs. Leave the throttle cable attached to the filter housing and move both assemblies out of the way to access the top wall of the fuel tank. There is a cover over the carb adjust screws that wiggles out also. The fuel line and purge line both pass through the wall of the tank and need to be pulled out with some effort (long curved forceps) from inside the tank through the fuel fill port. They are a tight fit. Pay attention to the lines size and location. Large line is in the position away from the recoil starter with the little plastic fitting hanging near the top of the tank. The smaller line is closest to the recoil starter. Both new lines will need to pass through the tank wall (this is the most difficult part). To facilitate the initial entry through the wall of the tank, cut a tapered end on your new lines. Use a very slippery lube to coat the end of the line and push it into the tank as far as you can from the top (forceps or soft grip pliers) help. Look inside the tank and pull the lines through fully out of the tank fill (long curved forceps and head spot light). Don't pull all the way through the fuel fill, just enough to install the new fuel line fitting in the return purge line and the new weighted filter on the fuel line and pull the lines back inside the tank. The return line with fitting close to the top of the tank and the filter hanging so it lays at the bottom of the tank, and able to swing around so it keeps contact with fuel at all times. Remove the old purge/primer bulb two screws (Phillips). The short stem is suction, long stem is pressure. Don't mix them up and connect lines backwards, don't ask me how I know! Lol! If you have such a saw like mine, that has no fuel lines intact, it is difficult to vision the line routes. There are helpful schematics on the internet. Just remember that the purge bulb long fuel stem sends pressure back to the tank through the return line (larger line in the tank with the line fitting away from the recoil). That line can now be cut to length and pushed on the bulb long stem. The suction side of the bulb short stem, connects to the purge line on the side of the carburetor (short line). You need to cut that line to the same length as the old one. It has to curve twice to get to the suction side of the purge bulb without kinking. The only other line left is the fuel line with the filter attached hanging inside the tank. Be sure you have the filter able to lay on the floor of the tank and move around. That line connects to the carburetor opposit side from the purge bulb. Dont cut that one until the carb is installed for proper length. The fuel routes from that filtered line into the carb, then out of the carb to the purge bulb suction side, then out to the return line in the tank with the fitting end. That fitting installed into the line serves only to keep the line from pulling back out of the tank, nothing attaches to it. Make sure all lines are clear of the mounting area of the carb, and throttle function. Pass the bulb lines through the slot in the side of the case being sure the lines don't kink. Secure the bulb with the two phillips screws. Position the carb on the studs and slide the choke lever into its place in the case as you go. Place the filter housing on the studs and push the carb and housing down watching the fuel lines for any kinks, especially where the throttle cable is in close proximity to the short carb purge line. Check the throttle function for interferance, and Install the two 8mm nuts. Now route the fuel line around the throttle mechanism out of the way, hold it to the barb on the side of the carb and cut it to length and install. Put some fuel mix in the tank (dont fill it) to test. Press the primer bulb, tilting the saw with fill cap removed, and see if anything leaks, also watch fuel flow back to the tank inside as you press the bulb. You should see fuel and air bubbles from the purge line. When all air bubbles are gone the system is purged. Install the new foam filter in the housing and then the top and side cases. I did not reinstall the cover of the carb adjust needle screws so I could adjust the fuel/ air mixture to run at peak performance. Hope this helps! The kit that I got was perfect and there are some useful instructions included. Thank you! Respectfully Mark

Replaced all fuel lines. Followed instructions found on Partselect.com, which said to insert cut fuel line in tank and use forceps to reach back in the tank and pull the fuel line through. The problem was that I did not have forceps, or needle nosed pliers that could reach the end of the hose.

Instead of running the line into the tank, I found another suggestion online to run the line from inside the tank outward, allowing me to grab the line with any pliers and thread it. The way I did this was used about a foot length of 14 gauge copper wire. Put an inch or two into the hose (that has been cut on an angle), and use a little black tape to secure the hose on the wire. Now you should be able to route the stiff wire from inside the tank to the fuel hole in the tank. Fish the wire through, and it should be enough to get the tapered end through the tank. Pull the copper wire, mine came out, but there was enough of the hose exposed on the outside of the tank for me to grab with pliers and pull it through.

Be sure the fuel line is the exact same size (id and od) as the one you are replacing. I had purchased a Fuel line from my local dealer - and after a few hours I figured out that it was the wrong size! He simply cut some line from a spool he had. Didn't bother to look it up! The line from this site was perfect! The id is important because the line has to Compress to go through the hole.