Replacing the fuel lines on a Troy-Bilt gas edger takes about 30 minutes and costs around $15 using the official Fuel Line Kit (490-240-0008).
A Troy-Bilt gas edger that won’t start or runs rough often has cracked, brittle fuel lines. Replacing them takes about 30 minutes with the official Fuel Line Kit (490-240-0008), which costs roughly $15.
What’s In The Troy-Bilt Fuel Line Kit?
The official fuel line kit for Troy-Bilt 4-cycle handheld engines includes two sizes of fuel-resistant rubber hose and the components needed to restore fuel flow from the tank to the carburetor. The kit is model 490-240-0008, available on the Troy-Bilt fuel line kit page.
Here’s a breakdown of the kit’s contents and compatibility:
| Component | Specification | Notes |
|---|---|---|
| Kit Part Number | 490-240-0008 | Official Troy-Bilt / MTD |
| Small Line | 1/16″ I.D. × 1/8″ O.D. | Fuel filter line |
| Large Line | 3/32″ I.D. × 3/16″ O.D. | Return line |
| Material | Fuel-resistant rubber | Smooth, flexible |
| Compatible Models | TB516 EC and other 4-cycle handhelds | Edgers, trimmers, blowers |
| Price Range | $12 – $18 | Tractor Supply, Appliance Parts Pros |
| Engine Type | 4-cycle only | Not compatible with 2-cycle engines |
How To Replace Fuel Lines On A Troy-Bilt Edger: The Correct Step Order
This procedure works for the TB516 EC and most Troy-Bilt 4-cycle handheld edgers. Work in a well-ventilated area with no open flames nearby. Wear gloves to protect your hands from fuel and grime.
1. Drain the fuel and disconnect the spark plug
Remove all fuel from the tank using a siphon pump. Pull the spark plug wire off the plug to eliminate any risk of accidental startup during the repair. Let the engine cool completely if it was running.
2. Remove the old lines
Disconnect the small line (fuel filter line) from the straight brass port on the carburetor. Disconnect the large line from the curved port. Use hemostat forceps or needle-nose pliers to pull both lines out through the fuel tank filler opening.
3. Install the new small line with filter
Cut the end of the small line at a pointed angle—this makes insertion into the tank hole much easier. Push it into the smaller tank hole and pull about 4 inches through the filler opening. Attach the fuel filter to the end, then push the filter back into the tank. Connect the other end of the small line to the straight brass port on the carburetor. The official Troy-Bilt fuel line kit (490-240-0008) includes both line sizes and the correct fuel filter.
4. Install the new large line
Cut the large line at an angle and push it into the larger tank hole. Pull enough through the filler opening to reach the carburetor without tension. Connect this line to the curved port on the carburetor.
5. Prime and test
Reconnect the spark plug wire. Fill the tank with fresh 100% unleaded gasoline. Press the purge bulb repeatedly until you see fuel flowing through the lines. Inspect every connection for leaks. If the bulb doesn’t fill, check that the lines are on the correct ports and aren’t kinked. The purge bulb fills and stays firm when the repair is done correctly.
Common Mistakes That Ruin The Repair
Most failed fuel line repairs come from a few predictable errors. Knowing them ahead of time saves you a second tear-down.
- Wrong port connection — The small line goes to the straight brass port, and the large line goes to the curved port. Swapping them stops fuel flow completely.
- Not cutting the line at an angle — A square-cut line end is hard to push through the tank grommet. A pointed, angled cut slides in easily.
- Skipping the spark plug disconnect — The engine can crank while you’re reaching inside the tank area if the wire is still hot.
- Using the wrong fuel — Troy-Bilt 4-cycle engines use pure unleaded gasoline only. Adding oil mix (as in 2-cycle engines) will damage the engine.
- Ignoring the purge bulb test — If you skip this step, you might fire the engine dry, which can damage the carburetor.
Is It Worth Fixing Your Edger?
A fuel line replacement costs about $15 and takes 30 minutes. If the engine still has good compression and the rest of the unit is in decent shape, the repair is a no-brainer. But if the blade shaft is bent, the engine smokes heavily, or the carburetor is rusted internally, it may be time to look at a replacement. For those cases, our tested picks for the best gas edgers can help you find a reliable upgrade.
Troubleshooting Fuel Flow After Installation
If the edger still won’t start or runs poorly after you’ve replaced the lines, check this table for the most common causes.
| Problem | Likely Cause | Fix |
|---|---|---|
| Engine won’t start | Lines connected to wrong carburetor ports | Small line to straight brass port; large line to curved port |
| Fuel leaks at tank grommet | Line end not cut at a pointed angle | Remove and re-cut the tip at 45° before reinserting |
| Purge bulb stays empty | Clogged fuel filter or pinched line | Check filter installation; ensure lines aren’t bent sharply |
| Engine runs briefly then dies | Air in fuel lines or stale fuel | Prime fully; drain and refill with fresh 100% unleaded gas |
| Lines pop off carburetor | Wrong size line or heat-damaged hose | Verify you used the correct kit sizes; replace if melted |
Final Repair Checklist
Before you call the job done, run through these six checks.
- Spark plug wire is reconnected securely.
- Fuel tank has fresh 100% unleaded gasoline.
- Small line is on the straight brass port; large line is on the curved port.
- Fuel filter is inside the tank and not floating in the filler neck.
- Purge bulb fills and stays firm after several presses.
- No fuel drips at any connection after 30 seconds of idling.
If everything passes, your Troy-Bilt edger is ready for another season of yard work.
FAQs
Can I use generic fuel line instead of the Troy-Bilt OEM kit?
Generic fuel line of the correct inner diameter (1/16″ and 3/32″) can work, but the OEM kit (490-240-0008) is only $12–$18 and includes the proper lengths plus the correct fuel filter. The kit’s rubber is formulated for ethanol-blend fuels and resists cracking longer than many generic options.
How do I know when the fuel lines need replacement?
Cracked, brittle, or hardened fuel lines are the clearest sign. A Troy-Bilt edger that stalls, won’t start, or runs erratically after sitting for months often has fuel lines that have degraded. If the rubber feels stiff or you see visible cracks near the carburetor connections, replace both lines.
Is the Troy-Bilt TB516 EC a 2-cycle or 4-cycle engine?
The TB516 EC is a 4-cycle engine, which means it uses pure unleaded gasoline in the tank and has a separate oil reservoir for lubrication. Do not mix oil into the fuel as you would with a 2-cycle trimmer. Using mixed fuel in this edger will damage the engine quickly.
Will this fuel line kit work on my Troy-Bilt string trimmer or blower?
Yes, if your Troy-Bilt handheld tool uses a 4-cycle engine with the same fuel line layout. The kit fits many TB-series trimmers, blowers, and edgers that share the TB516’s 4-cycle engine platform. Check your model against the compatibility list on the Troy-Bilt product page for the 490-240-0008 kit.
Does replacing the fuel lines fix an edger that sat with old gas for years?
New fuel lines are the first step, but old gas that turned to varnish may have gummed up the carburetor. After replacing the lines, if the engine still won’t start or runs poorly, the carburetor likely needs cleaning or rebuilding. The fuel line replacement alone handles the rubber degradation, but not internal carburetor deposits.
References & Sources
- Troy-Bilt. “Fuel Line Kit – 490-240-0008.” Official product page with specs and model compatibility.
- Repair Clinic. “Troy-Bilt Lawn Mower Fuel Line Replacement.” Step-by-step repair guidance and parts lookup.