A minor repair made to the fuel supply system of a Model 2150 Poulan chainsaw after the saw ceased to function properly.

Background

When I bought a Poulan 2150 gas chainsaw (16″ bar) a few years ago to do some light work around the back yard and in the bush behind our home, I did so without doing any research on the brand or the saw itself. The saw was reasonably-priced and it worked very well for all the jobs I gave it.

At the end of last fall, when I put the saw away for the winter, it wasn’t running very well and I had a very difficult time getting it to start or run from cold. As it wasn’t convenient to tear it apart at the time, I went on-line to see if I could find out about the saw, the brand and any others’ experience with this lightweight saw.

Research

I found, to my surprise, that Poulan had been manufacturing chain saws for many years, and has been in business since at least 1944. I had not heard much of this company before I bought the saw. I also discussed the difficulties I was having with my friends and relatives who had saws. From what I could gather, almost no-one thought the saw was worth having and thought it was also unreliable. I also found out on-line that a weak point was failure of the fuel-line.

Diagnosis

After removing the appropriate screws and cowling, I could get at the carburetor and proceeded to remove the fuel line from the spigot on the carburetor. The fuel line (which looked like plastic, Tygon, or the like) fell apart in my fingers. Each time I attempted to shorten the fuel line to find a better section, the line crumbled away. Obviously, this was a real problem, and this could easily explain the difficulties I was having with the operation of the saw. I checked the rest of the tubing which extended into the fuel tank through a hole in the casing and was attached to the fuel filter. The fuel filter was sitting loose in the bottom of the tank, obviously not connected to anything.

Repair

After removing all remaining traces of the main fuel line from the carburetor area and from the fuel tank, I flushed out the fuel tank and then went shopping for new fuel line and possibly a new fuel filter. None of the hardware stores and repair shops close by had anything suitable. I finally traveled farther afield and found a supplier for both items. However, when I attempted to insert the new fuel line through the casing, there was no easy way (and I tried different suggested methods) to get the fuel line through the plastic casing. The tubing was just too large in diameter. Against my feelings, I drilled out the plastic through hole in the casing so that the tubing was a good fit (tight) and re-assembled all with a new filter in place.

I suppose what this means is that I will have to replace the fuel line every couple of years as this tubing will likely dissolve in the gasoline as well. At least now, I can buy readily-available fuel line from not-too-distant supplier that will fit without trouble.

This is just a small repair but it saved me some money for repairs and gave me a usable saw again.

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  • Will on May 26, 2009

    I had similar problem with fuel lines, I resolved this fitting problem by using wire cutters to shave off half of the lines diameter for about an inch. That made the line easier to push through the hole and grab it with needle nose pliers wich then pulled easily through hole.

  • Raymond on Jun 6, 2010

    If you cut the end of the fuel line on a 45 degree angle this will make it simpler to feed through the hole in the casing.The angle allows the line feed while aiso causing it to compress slightly keeping the tight fit to aoid leaks.

  • Jack on Sep 3, 2010

    Same thing happened with (3) Poulan saws I own, including the 2150. Apparently the original tubing was PVC, which gets deplasticized. Replacements are Tygon. Angled cut on new line, and needle-nose or hemostat, gets it installed.
    ALWAYS use a fuel filter.
    Often when line fails like this, debris clogs inlet screen in carb, mandating teardown. It did with 2 out of 3, for me.
    How much did mfg. save? fifteen cents?

  • larry on Nov 15, 2010

    I have a Poulan WoodShark #1950 with same problem. Lowes has a weedeater hose pack with 2 sizes of hose,small one fits my weedeater, larger one looks like it will fit my chainsaw. i\’ll find out tomorrow.

  • Dartman on Nov 26, 2010

    I am glad I wasn’t alone with my problems. It seems the Poulan design could have been better from a reliability point-of-view. Thanks for the comments and suggestions, all.

  • Richard Geringswlad on Jan 2, 2011

    Same problem but how do you configure the lines? There is a push button primer on my Craftsman 14″ and it split and I replaced it, but where do the hoses and filter go as all hoses disintegrated and there was nothing to go by.

  • Farmer49 on Feb 10, 2011

    One line with the fuel filter goes to the pump side of the carb. Then one line from the fuel tank goes to the primer on the suck side. The line coming out then goes to the carb. On my poulans the primer went to the bottom tube on the carb. Mine had a WT warbo carb. I am not an expert so I don’t know if this helped. I also have Stihl saws, much better but cost more. When you hook up the primer pump to see if you are getting fuel through it before puttin on the carb., if not reverse the lines. Get the right size line as it could press down enough to keep the motot from geting enough fuel supply.

  • Dartman on Feb 20, 2011

    Thanks for the input Farmer49. My manual does not show this fuel line routing detail well and I struggled a bit to get things working properly. Unfortunately, I have given the saw away now as further difficulties with it drove me to being emotional and giving it to the repair shop for the time they had spent on it.

  • Roy on Jun 25, 2011

    The ethanol in todays gasoline is NO help in this matter. A new product called “Startron” has been introduced to the marketplace. It is rumored to counteract the detrimental effects that 10% ethanol (common now) in our US gas has on small engines and equipment. I just replaced fuel lines today (Tygon, by hand, without drilling) and it was very slow and tedious as the fit was extremely tight going in thru the 2 different sized holes (supply-small…return-larger). It takes a lot of patience to work on these machines, but once you understand most of their ills, it is not too hard. Fuel line deterioration is an extremely common malady and one that causes many people to abandon using that piece of equipment. Fuel line fixes are not too bad, as you have said…it is the Chinese design and engineering that is BAD. By the way, my Poulan 1950LE says assembled in USA (and they don’t mention the foreign parts)!

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