DIY Chain Saw Gas Leak Repair

Written by eric blankenburg
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DIY Chain Saw Gas Leak Repair
Storing your chainsaw properly reduces gas leaks. (Brand X Pictures/Brand X Pictures/Getty Images)

The fuel system of a chain saw is one of its most vital components and should be serviced regularly according to the ChainsawHub website. Dirt, debris, cracks or holes in the fuel system can cause a severe loss in power and gas leaks in the tank and carburettor. This in turn can damage to your carburettor, piston and cylinder. That's why it's important to make sure the carburettor is getting clean fuel, according to M & D Mower and Appliance.

Skill level:
Moderately Challenging

Things you need

  • Rag
  • Toothbrush
  • Needle-nose pliers
  • Gas cap
  • Fuel line
  • Fuel filter
  • Scissors

Show MoreHide


  1. 1

    Wipe the fuel tank's exterior clean with the rag. Inspect the plastic closely for any small holes or punctures, which could be causing your gas leak. If holes are present, you will need a new gas tank, a repair that should be performed by a mechanic.

  2. 2

    Unscrew and remove the fuel tank's cap. Scrub all surfaces of the cap with the toothbrush and a little gas from the tank. Wipe it clean with the rag. Inspect the cap's inner seal and threads for damage or severe stripping.

  3. 3

    Inspect the check valve -- a small hole on the gas cap used to vent exhaust -- to make sure that it's clean and unobstructed. Replace the cap if it is bent, broken or damaged in anyway.

  4. 4

    Pour out any remaining gasoline into an approved fuel container. Scrub the inner walls of the tank with the toothbrush and rag. Inspect the tank for signs of leakage and replace it if necessary. Follow the manufacturer's directions for removing the tank and installing a new one.

  5. 5

    Unscrew and remove the air filter cover, which usually sits below the top handle bar. Identify the carburettor, which typically is located in front of the air filter's mounting plate. On some saws, you have to unscrew the two mounting screws on the choke cover, above and below the filter's mounting plate. Disconnect the plastic gas lines from the two elbow connectors on the carburettor, using the needle-nose pliers.

  6. 6

    Grab the small fuel filter sitting at the bottom of the fuel tank, using the needle-nosed pliers. Pull the filter and fuel line from the engine with the pliers. Discard the fuel line and filter.

  7. 7

    Push the new fuel line through the hole in the tank's bottom until it emerges near the carburettor. Connect both gas lines to the carburettor with the needle-nose pliers. Leave 1 to 2 inches of fuel line in the tank to ensure the chain saw will operate when tipped to the side. Cut off the excess fuel line with scissors.

  8. 8

    Install a new fuel filter by pushing the filter's nozzle into the fuel line inside the tank. Push the filter and line back into the tank.

  9. 9

    Fill the chain saw with fresh fuel. Check to see if leak is still present. If it is, you most likely have a problem with your carburettor, which should be serviced by a mechanic.

Tips and warnings

  • Always use caution when working around flammable materials.
  • Never leave fuel inside the tank when not running the chain saw for more than 48 hours.

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