A leak can start in one of several places in a fuel system. From the tank to the return pulse line, the whole system should be checked to determine the origin of any leaks and any additional possible leaks. While most of these gas leak repairs can be performed with a few simple tools, if you don't feel qualified performing them, then you should take the saw to a qualified professional.
- Skill level:
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Things you need
- Needle-nosed pliers
- Metal hook (baling wire)
- New fuel line
- New fuel filter
- Carburettor pressure gauge
- Carburettor cleaner
- Carb kit
Screw the gas cap on tight and hold the engine upside down to see if any fuel leaks from the tank area. Unscrew the gas cap and check the rubber seal on the inner ring of the gas cap. Inspect the gas tank for any warping, cracks or holes. If holes or leaks are present, you will need to replace your fuel tank.
Pour any remaining fuel into an approved fuel container. Start the chainsaw and run it until it shuts off, to purge any fuel remaining in the system. Unscrew the cylinder cover's four retaining screws. The cylinder cover sits in between the starter cover and the clutch cover. Take the cover and screws off of the engine.
Disconnect the fuel line from the inlet valve on the carburettor using the needle-nosed pliers. Bend the metal wire into a hook and reach into the tank and pull out the fuel filter and fuel line. Remove the fuel line and fuel filter from the engine and throw them away.
Unscrew the screw holding the air filter's mounting plate to the crankcase. Unscrew the two screws holding the choke plate and carburettor to the intake manifold. Pull off the air filter mounting plate and the carburettor with the connected throttle linkage from the crankcase.
Unscrew the intake manifold's two retaining screws and remove it from the crankcase. Remove the rubber seal and gasket underneath the intake manifold. Inspect these parts for any damage. Worn seals or gaskets can leak gas. Replace these parts as necessary.
Hook the pressure gauge nozzle up to the fuel inlet valve on the carburettor. Submerge the carburettor into the bowl of fuel. Pump the pressure gauge up to 7.1 psi. There should be no air leaks and the carburettor should be able to hold positive pressure.
Unscrew the metering diaphragm cover on the carburettor if leaks are present. Remove the metering diaphragm and its gasket from the carburettor. Check the diaphragm for warping or cracks.
Unscrew the lever shaft and remove the lever, needle valve and spring from the carburettor. Inspect these parts for damage; make sure the needle valve can be properly seated on the lever. Replace these parts if they are worn or misshapen.
Unscrew the fuel pump cover's screw and remove the cover. Pull out the fuel pump diaphragm and its gasket from the carburettor. Inspect these parts for damage or warping. Replace as necessary.
Pull off the screen inside the fuel inlet passage. Remove the low and high speed mixture screws from the carburettor. Replace the screen and mixture screws. Soak all of the disassembled carburettor parts in a carburettor cleaner bath.
Reassemble the carburettor using a carb kit. Replace all of the seals, gaskets, covers, screens, filters and Welch plugs. Repeat carburettor pressure test. If carburettor still won't hold positive pressure you will need to replace the carburettor.
Reinstall the carburettor and replacement fuel line and fuel filter. Reassemble rest of parts in reverse order. If fuel leaks are still present you will need to check the crankshaft seals, crankshaft and crankcase for damage. These repairs should only be done by qualified professionals.
Tips and warnings
- When disassembling, cleaning and rebuilding the carburettor extreme care is needed to ensure permanent damage isn't done to the carburettor's smaller parts.
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