Difficulty

Moderate

Steps

30

Time Required

                          45 minutes            

Sections

1

  • Primer Bulb, Fuel Lines, Filters
  • 30 steps

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0

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Introduction

What you need

Step 1

              Primer Bulb, Fuel Lines, Filters               
  • Unscrew the three T25 screws on the top cover.
  • Remove the top cover and set aside.

Unscrew the three T25 screws on the top cover.

Remove the top cover and set aside.

1024

Step 2

  • With the top cover off, disconnect the spark plug.

With the top cover off, disconnect the spark plug.

Step 3

  • Remove the four T25 screws securing the starter assembly to the (side) of the chainsaw.
  • Remove the starter assembly and set aside.

Remove the four T25 screws securing the starter assembly to the (side) of the chainsaw.

Remove the starter assembly and set aside.

Step 4

  • Remove the air filter cover and set aside.
  • Remove the air filter from the housing and set aside.

Remove the air filter cover and set aside.

Remove the air filter from the housing and set aside.

Step 5

  • Unscrew the single T25 screw securing the air filter housing to the carburetor.
  • Remove the two 5/16"nuts securing the air filter housing to the carburetor.

Unscrew the single T25 screw securing the air filter housing to the carburetor.

Remove the two 5/16"nuts securing the air filter housing to the carburetor.

Step 6

  • Use a spudger or flat head screwdriver to disconnect the kill switch wire.

Use a spudger or flat head screwdriver to disconnect the kill switch wire.

Step 7

  • Remove the air filter housing from the carburetor.
  • Let the air filter housing rest on the side of the chainsaw.

Remove the air filter housing from the carburetor.

Let the air filter housing rest on the side of the chainsaw.

Step 8

  • Using a flat head screw driver or opening tool to disconnect the (primer-side) fuel line from the carburetor.

Using a flat head screw driver or opening tool to disconnect the (primer-side) fuel line from the carburetor.

Step 9

  • Remove the choke lever from the carburetor and set aside.

Remove the choke lever from the carburetor and set aside.

Step 10

  • Pull and hold the throttle trigger to expose the throttle linkage attachment point (on the trigger).
  • Disconnect the linkage from the throttle trigger.
  • Disconnect and remove the throttle linkage from the carburetor.
  • Set the throttle linkage aside.

Pull and hold the throttle trigger to expose the throttle linkage attachment point (on the trigger).

Disconnect the linkage from the throttle trigger.

Disconnect and remove the throttle linkage from the carburetor.

Set the throttle linkage aside.

Step 11

  • Slide the carburetor assembly off the mounting bolts and away from the engine.
  • The fuel return line may still be attached to the carburetor. In my case the fuel line was disintegrated. If it is still attached remove with a flat head screw driver or spudger.

Slide the carburetor assembly off the mounting bolts and away from the engine.

The fuel return line may still be attached to the carburetor. In my case the fuel line was disintegrated. If it is still attached remove with a flat head screw driver or spudger.

Step 12

  • Using a flat head screwdriver or spudger to press the tabs on the inside of the primer bulb assembly. (This will release the primer bulb from the housing).
  • Pull the damaged primer bulb out of the engine housing.
  • Use long needle nosed pliers to disconnect the two fuel lines from the primer bulb.

Using a flat head screwdriver or spudger to press the tabs on the inside of the primer bulb assembly. (This will release the primer bulb from the housing).

Pull the damaged primer bulb out of the engine housing.

Use long needle nosed pliers to disconnect the two fuel lines from the primer bulb.

Step 13

  • If the primer suction line was damaged, slide the carburetor back onto the mounting bolts.
  • Attach one end of the new fuel line to the incoming fuel port on the carburetor.
  • Move the fuel line through the primer bulb housing and hold the primer bulb up to the fuel line.
  • Mark desired length and cut to size.
  • If the old primer suction line was intact, you can measure and cut a new piece of fuel line to the same length and attach it to the intake port on the primer bulb and intake port on the carburetor.

If the primer suction line was damaged, slide the carburetor back onto the mounting bolts.

Attach one end of the new fuel line to the incoming fuel port on the carburetor.

Move the fuel line through the primer bulb housing and hold the primer bulb up to the fuel line.

Mark desired length and cut to size.

If the old primer suction line was intact, you can measure and cut a new piece of fuel line to the same length and attach it to the intake port on the primer bulb and intake port on the carburetor.

Step 14

  • Attach the cut end of the primer fuel line to the intake port of the primer bulb (shorter nipple).
  • Slide the carburetor back off of the mounting bolts.
  • Cut and remove the remaining old fuel lines by pulling them through the housing.

Attach the cut end of the primer fuel line to the intake port of the primer bulb (shorter nipple).

Slide the carburetor back off of the mounting bolts.

Cut and remove the remaining old fuel lines by pulling them through the housing.

Step 15

  • Unscrew and remove the gas cap.
  • Pull out and remove old fuel lines and fuel filter.

Unscrew and remove the gas cap.

Pull out and remove old fuel lines and fuel filter.

Step 16

  • This is an example of how the fuel lines will attach to the carburetor and primer bulb

This is an example of how the fuel lines will attach to the carburetor and primer bulb

Step 17

  • Push a piece of scrap wire through the larger hole (fuel filter line)
  • Use a pair of long needle nose pliers or hemostats to grab the other end through the gas tank

Push a piece of scrap wire through the larger hole (fuel filter line)

Use a pair of long needle nose pliers or hemostats to grab the other end through the gas tank

Step 18

  • Cut a piece of the thicker diameter fuel line at a sharp angle
  • Pierce the wire through the fuel line and twist the wire with pliers

Cut a piece of the thicker diameter fuel line at a sharp angle

Pierce the wire through the fuel line and twist the wire with pliers

Step 19

  • Feed the fuel line through the gas tank while pulling the wire.
  • Use pliers to continue to pull the fuel line through the housing

Feed the fuel line through the gas tank while pulling the wire.

Use pliers to continue to pull the fuel line through the housing

Step 20

  • Feed the wire through the small hole (fuel return)
  • Attach the wire to the cut end of the thinner diameter fuel line as in the previous step
  • Feed the fuel line through the gas tank while pulling the wire as in the previous step
  • Pull both fuel lines up through the housing

Feed the wire through the small hole (fuel return)

Attach the wire to the cut end of the thinner diameter fuel line as in the previous step

Feed the fuel line through the gas tank while pulling the wire as in the previous step

Pull both fuel lines up through the housing

Step 21

  • Using 2-cycle oil as lubricant on the fuel lines will make it easier to pull them through the housing

Using 2-cycle oil as lubricant on the fuel lines will make it easier to pull them through the housing

Step 22

  • Cut both of the fuel lines flush (removing the angle that was previously cut)

Cut both of the fuel lines flush (removing the angle that was previously cut)

Step 23

  • Attach the larger diameter fuel line (fuel filter line) to the intake inlet on the carburetor
  • Attach the smaller diameter fuel line (fuel return line) to the return port on the primer bulb (longer nipple)
  • Slide the carburetor back onto the mounting bolts while pulling out the slack out of the fuel lines from the gas tank

Attach the larger diameter fuel line (fuel filter line) to the intake inlet on the carburetor

Attach the smaller diameter fuel line (fuel return line) to the return port on the primer bulb (longer nipple)

Slide the carburetor back onto the mounting bolts while pulling out the slack out of the fuel lines from the gas tank

Step 24

  • Push the primer bulb back into the housing
  • Cut the smaller diameter fuel line (fuel return line) and push it into the gas tank
  • The fuel return line should be at the bottom of the tank

Push the primer bulb back into the housing

Cut the smaller diameter fuel line (fuel return line) and push it into the gas tank

The fuel return line should be at the bottom of the tank

Step 25

  • Cut the fuel filter line and attach the new fuel filter
  • Push the fuel filter line into the gas tank
  • The fuel filter should rest at the bottom of the gas tank

Cut the fuel filter line and attach the new fuel filter

Push the fuel filter line into the gas tank

The fuel filter should rest at the bottom of the gas tank

Step 26

  • Reconnect the throttle linkage to the carburetor linkage
  • Pull and hold the throttle trigger to expose the attachment point for the trigger-portion of the throttle linkage
  • Connect the throttle linkage to the throttle trigger

Reconnect the throttle linkage to the carburetor linkage

Pull and hold the throttle trigger to expose the attachment point for the trigger-portion of the throttle linkage

Connect the throttle linkage to the throttle trigger

Step 27

  • Reconnect the choke lever
  • Slide the air filter housing back onto the carburetor mounting bolts
  • Secure the air filter housing with the (2) 5/16" nuts
  • Secure air filter housing with (1) T25 screw

Reconnect the choke lever

Slide the air filter housing back onto the carburetor mounting bolts

Secure the air filter housing with the (2) 5/16" nuts

Secure air filter housing with (1) T25 screw

Step 28

  • Install the new air filter onto the air filter housing
  • Install the air filter cover
  • Connect the kills witch wire

Install the new air filter onto the air filter housing

Install the air filter cover

Connect the kills witch wire

Step 29

  • Install the starter assembly onto the engine
  • Secure the starter assembly with (4) T25 screws
  • Pull the starter rope slowly until the flywheel engages the starter assembly

Install the starter assembly onto the engine

Secure the starter assembly with (4) T25 screws

Pull the starter rope slowly until the flywheel engages the starter assembly

Step 30

  • Reconnect the spark plug
  • Install the top cover and secure with (3) T25 screws

Reconnect the spark plug

Install the top cover and secure with (3) T25 screws

To reassemble your device, follow these instructions in reverse order.

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Author

                                      with 3 other contributors 

                    Chad Monteleone                     

Member since: 09/18/2017

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                       Pasco Hernando, Team S4-G44, Prince Fall 2017                        

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                                            4 Guides authored                     

Daniel - Jan 31, 2018

Reply

Any idea where I downloaded shop manuals for small engin repairs looking for stihl 039 manual

Randy Clawson - May 17, 2021

Yes I would try manuals.lib at the Google play store.

Robert Spillman - Jul 28, 2019

Reply

Daniel. Here you go. Hope this works out for you.

https://m.stihlusa.com/WebContent/CMSFil

Ron Bishop - Oct 19, 2019

Reply

Excellent instructions

Thank You

ross jonnes - Nov 4, 2019

Reply

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