Poulan Chainsaw Repair - How to Replace the Fuel Return Line

Need help replacing the Fuel Return Line (Part # 530069247) in your Poulan Chainsaw? Watch this how-to video with simple, step-by-step instructions for a successful DIY repair.

Don’t already have this part? You can pick up an authentic OEM part sourced directly from the original manufacturer here:

Fix Part Number: FIX9472280
OEM Part Number: 530069247

Why you might need to replace the Fuel Return Line:
1. Gas Leaking From the Engine
2. Engine Won't Start

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[robertcrotts]

that is the cleanest chainsaw i have ever seen

[Uncommonene]

Other than forgetting to attach the fuel filter/tank line to the fitting before pulling the fitting back into place, this was a great video! If the process is completed according to this video you'll end up with no fuel filter and no line leading into your fuel

[toprudder]

It is really hard to push the fuel tubing through the hole in the tank, since the tubing has to be large enough to form a seal in the hole. I tried cutting the tubing at an angle, and that helped, but I figured out an easier way. Heat the tubing up with a heat gun and stretch a section of the tubing, which causes the diameter to shrink. Cut the tubing where the diameter is the smallest. Now feed this end into the hole (either from the inside or outside of the tank, whichever is easier) and pull through using a hemostat. Now cut off the stretched part of the tubing. A small amount of the tubing is wasted using this method, but it is well worth it in time and frustration.

[dalecallaham]

Very nice video. It does kind of gloss over the difficulty of pushing the tubing through the gas tank wall since the tubing gets fatter as you push against the tight hole. The fuel lines pass through the gas tank wall with no gasket: the fuel line has to be slightly oversize to make a nice seal. Oversize tubing is hard to push through the hole since the tubing compresses and gets fatter, making the whole thing even harder. I found a solution. I cut the end at a bevel, then took a double strand of strong #92 polyester thread on a needle, poked the needle through the beveled end, then looped the knotted thread ends over the tubing.

Drop the needle into the gas tank hole and reach in with hemostats (or fine needle-nose pliers) and pull the needle and thread and tubing into the gas tank. By pulling (and even stretching a bit by pulling back from the outside end, the tubing gets thinner and will slide through. When you get a bit pulled down into the tank you can reach in with hemostats (or fine needle nose pliers) and pull on the tubing itself. When you have enough pulled through to come out the gas tank opening, cut off square and install the fuel filter or other fitting, then adjust the length in the tank by pulling back out as needed.

In the case of the fuel intake and filter, leave enough tubing in the tank so that the filter lies on the bottom of the tank even if the saw is rocked 90deg for horizontal cutting. In the case of the return line, pull the line so as to pull the nylon barb fitting to the "roof" of the tank.

[devopro]

It's a very informative video. I wish I had a pair of those heavy hemostats laying around.

[lindafindley-ub]

Used twice the length of gas tube & cut about 1 1/2 inches into half to feed thru narrow hole where I could see & catch the end in the gas tank. Too many years of pulling electrical lines using a fish line. great Video!!!

[ETHRON]

At 17 seconds you showed me what I needed to know...thank you.👍

[igywoodcreations]

Best illustration video of this kind. Thank you for making this process clearly.

[BeckVMH]

All looked good until you mentioned I would need a hemostat! Seems like a nice video although I haven't watched the entirety. Professionally done with a proper camera that's held stable with proper light and proper audio, thanks! I can actually watch without getting seasick.

[ronnielintz]

Excellent vid. Very detailed explanation.

[hardnoxgrad]

The best one of the 18 others i watched before this one.👍🏻🇺🇸🇺🇸🇺🇸 Thank You Sir.

[Tailu]

TY It helped my repair my Homelite, The line inside my gas tank had totally disintegrated.

[jameswhittington]

very good, now I can go back to my repairs, Thanks

[thejonegcle]

my Craftsman (poulan) chainsaw has both lines same right side of carb. also used 2 different size lines: small for primer - large for fuel tank. AND had fuel filter.

[rickgartrell]

Does it matter which port on the primer bulb connects to the fuel line return? I was told that the return line should connect to the longer stem.

[Jonathan-fxpr]

Thanks for the detailed information. This is the 3rd video I’ve watched on this and only now do I understand what each line does.

[brandoncox]

Would’ve helped a lot if you said which line is going to which male end on the primer bulb. You’ve got a short & long on the primer bulb

[volkmarmaleika]

While you were screwing the cover back on near the end of your video, I noticed a H/L hole on the side of the cover. Can someone till me what this function is for? I just got this saw last week without a owners book. THANKS

[matthewkendall]

I don’t understand how you got the fuel lines into the gas tank. I have been trying to shove the damn things into the hole for 30 minutes and it just scrunches up and refuses to go through! I even cut the tip at an angle to try and help get it through!

[sriceu]

Ok what about the fuel filter ? I didn't see that get installed