Poulan Saw Problem

rusty6 · Sep 4, 2017

Anybody had a problem with the fuel cap on a Poulan Pro Classic 16 chain saw like this? It was ok when new a few years ago but it began to get very tight . To the point that I need a pry bar to unscrew the plastic cap. Same thing to turn it back on. The threads are ok and it seals up tight with no leaks. Just seems like the cap has swelled and is so tight that it barely fits. I'm living with it but am afraid one of these days the cap is going to break when I have to pry on it so hard. Even used channel lock pliers to get it to turn.

D beatty · Sep 5, 2017

I have an Echo , stihl ,And husky that does that. Top photo is Echo cap and other is Stihl and caps have slot in them to use this tool to
open them.

2x4 · Sep 5, 2017

try a little grease & buy an extra cap to keep on hand.

Robert Major · Sep 5, 2017

Hi We had a few of those saws do that when Dad thought Poulan was the best saw to own. He even spent hours building one out of 3 when they all got
something different wrong with them L.O.L. He runs an Echo now and I never hear about Poulans, or have had a gas cap problem so far in 3 years of the
echo.

With his I got mad with the tight cap one day I just ran the cap round the bench grinder wheel, and lightly took some off the thread outside diameter
Until it screwed in again nice by hand. It was a bit fiddly doing it but it worked for quite a while before the saw finally died.
Regards Robert

Butch(OH) · Sep 5, 2017

I have a Shindaiwa that does the same
thing.

RESLLS · Sep 5, 2017

Have one I got for $30 when Target quit
selling saws. Does that when I use ethanol
fuel, especially if I leave it in the tank. Switched to non eth and it shrank back to original size. On the arborist forums it is a common problem. Some file it down. New cap does the same after a year or so. Gasket for my motorcyle cap swells up if I use ethanol fuel too.

Bret4207 · Sep 5, 2017

I bet you're using a gas with ethanol in it. Try a higher grade non-ethanol fuel and see if that fixes it.

Indiana Ken · Sep 5, 2017

I suspect you will find the interference is in the thread area - from my experience. I cut the thread OD down about .040" in a lathe. That helps but does not completely correct the problem.

JDEM · Sep 5, 2017

Yes, I have the same problem with the same saw. Worked fine when new and only the gas cap does it. Oil cap works fine. Type
of gas I use makes NO difference. Threads swell up. I tried buying a new cap. It swelled up just like the old one. I took
a razor knife and shaved the threads down. It now works.

Odd thing is my other el-cheapo Poulan Pro model 295 does not have the problem but it has a different design cap.

Deutz Lover · Sep 5, 2017

I have had the same problem on my Poulan Pro saws. I find it cheaper time wise to just buy extra caps at the small engine repair shop. I did not have the problem on my Husqvarna 51. I do like the PPs except having to replace the fuel lines every so many years when they disintegrate.

rusty6 · Sep 5, 2017

I like the thread cutting idea and might try it on my fuel cap to make it fit better. The oil cap is a little tight too but not as bad as the
fuel cap. I don't think our fuel has ethanol here in Canada. Only one grade available that I know of and I use it in everything. This Poulan
works great otherwise and is the best $100 chain saw I've ever owned.
Poulan working

Case Nutty 1660 · Sep 5, 2017

I agree 100% that is why I only use the highest grade fuel here as it does not have that nasty stuff in it
cnt

cuby · Sep 5, 2017

My Cfaftsman saw does the same thing. Will try shaveing some off.

shaun wallace · Sep 5, 2017

I have same problem with my poulan. Have couple extra caps, just lay up let dry out, when swells change to different one.

GVSII · Sep 5, 2017

(quoted from post at 07:10:53 09/05/17) My Cfaftsman saw does the same thing. Will try shaveing some off.

Lots of craftsman saws were rebadged paulans

Russ from MN · Sep 5, 2017

Ethanol gas! I must've gotten some by mistake once because I had the same problem, in a couple of years it shrunk back to normal size.

JDEM · Sep 6, 2017

I tried using the high-priced non-ethanol gas. It made NO difference. Gas cap still swelled up. I have to laugh at all the things I hear get blamed on 10% ethanol gas. I have not experienced any problems. I also just did a gas mileage test with my little motorhome. Drove 800 miles with regular gas and 10% ethanol and got 22 MPG. Drove another 800 miles with non-ethanol mid or high-test and guess what? Got 22 MPG.

Here in the Upper Peninsula of Michigan - non-ethanol during summer and fall is only available in high-test only. Waste of money.

Bret4207 · Sep 7, 2017

I believe it depends on where you live and the specific blends and what you are using it in. In a car or truck it makes no diff I've seen. In small engines, it can be a killer. You and I both have old saws. You put a 10% ethanol fuel mix in an old Pioneer and I can tell you that within 2 days you will need Channel Locks to get the plastic cap off. Then the fuel line will turn into a gummy worm a few days later. Change the fuel and the cap will return to more or less normal in a few weeks.

Anyone that hasn't had trouble with ethanol blends in small engines is lucky. Your luck doesn't mean the rest of us that have are fools or liars.

Poulan Saw Problem

rusty6

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D beatty

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2x4

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Robert Major

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Butch(OH)

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RESLLS

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Bret4207

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Indiana Ken

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JDEM

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Deutz Lover

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rusty6

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Case Nutty 1660

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cuby

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shaun wallace

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GVSII

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Russ from MN

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Bret4207

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