40v Ryobi chainsaw disassembly and fixing leaks
This video disassembles a 40V Ryobi cordless chainsaw to locate and repair oil leaks in the bar/chain lubrication system. The host removes the bar and chain, opens the clutch cover and housing, inspects and services the oil pump, replaces worn O-rings/seals or tubing, then reassembles and tests the chainsaw for proper oil flow.
Build Sequence
1. Safety and preparation
Remove the battery pack and place the chainsaw on a stable work surface. Clean the exterior to reduce mess during disassembly and collect basic tools. Wear gloves and eye protection.
2. Remove bar and chain
Release chain tension and remove the bar nuts or clutch cover to lift off the guide bar and chain. Inspect the bar groove, oil holes, and chain for excessive wear or damage.
3. Open clutch cover and housing
Remove screws/bolts holding the clutch/side cover and any body panels necessary to access the oil reservoir, oil lines, and oil pump. Keep fasteners organized.
4. Inspect oil reservoir and fill cap
Check the oil fill cap and its gasket for cracks or missing seals. Inspect the oil tank for cracks and the oil level sender or float for damage. Replace cap/gasket if leaking.
5. Inspect and test oil feed tubing
Trace the oil tubing from the tank to the pump and the pump to the bar. Remove and examine tubing for cracks, kinks, or loose fittings. Replace any brittle or cracked tubing.
6. Access and service the oil pump
Remove the oil pump from its mounting. Clean buildup and debris out of the pump body and inlet/outlet passages. Replace worn O-rings and seals or swap in a replacement pump if cleaning doesn't restore function.
7. Replace small seals and reassemble oil path
Install new O-rings/seals on mating surfaces and tubing connections, route new tubing where needed, and reattach the pump and reservoir components. Ensure hose clamps or fittings are snug but not over-tightened.
8. Reinstall bar and chain, tension and lube
Reinstall the guide bar and chain, set the proper chain tension, and torque bar nuts/cover to spec if known. Fill the oil reservoir with bar oil and check the fill cap for leaks.
9. Test run and leak check
Reinstall the battery and run the chainsaw at low speed while observing oil flow to the bar and checking for leaks from the tank, pump, or tubing. Make adjustments or re-seal as necessary.
10. Final cleaning and torque check
Wipe away any leaked oil, confirm fasteners are secure, and verify chain lubrication during a short cutting test. Monitor for new leaks after first use.
Frequently Asked Questions
How do I know if the leak is from the oil pump or the tank?
Visually trace where oil accumulates: if oil pools under the reservoir or around the fill cap the tank or cap gasket is likely at fault; oil trailing toward the bar or leaking from the lower housing usually points to the pump or feed tubing. Removing covers and running a brief test helps isolate the exact leak point.
VIEW FULL ARTICLE →Can I fix the leak without buying a new pump?
Often cleaning the pump, replacing small O-rings and the feed tubing, and reseating the fill cap will stop leaks. Replace the pump only if cleaning and seal replacements don't restore proper oil delivery or if the pump body is cracked.
VIEW FULL ARTICLE →How much does it typically cost to repair an oil leak on a Ryobi 40V chainsaw?
Minor repairs using O-rings, tubing, and seals can be under $20. Replacing the oil pump or guide bar/chain will increase cost — a full set of parts for this kind of repair typically runs around $60–$120 depending on parts chosen.
VIEW FULL ARTICLE →Will oil leaks affect battery or motor performance?
Leaking bar oil doesn't usually affect the battery or motor electrically, but oil contamination can attract debris or foul moving parts. Persistent leaks may reduce lubrication to the chain and increase load, potentially stressing the motor over time.
VIEW FULL ARTICLE →What safety precautions should I take before disassembling the chainsaw?
Always remove the battery pack, wear gloves and eye protection, work on a stable surface, and ensure the chain is immobilized or removed before handling the bar/chain to prevent accidental cuts.
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Used if the chain or guide bar is worn or damaged; optional for oil-leak repair
Common source of oil leaks — replacement recommended if cleaning doesn't restore function
Small O-rings and seals used on pump, oil tank, and oil line connections; inexpensive and often replaced during repair
Flexible tube that delivers oil from reservoir to pump/bar — can become brittle or cracked