Replacing Stihl Fuel Cap: Step-By-Step Guide For Beginners

Stihl fuel caps are a common issue for owners of Stihl products. The problem often lies in the plastic reacting to the gas, causing it to swell and making the cap hard to remove. This issue has been acknowledged by Stihl, who issued a recall for certain products in 2024. The recall was due to the risk of fire if fuel spillage occurred as a result of the difficult-to-remove caps. Replacement caps can be purchased online or from Stihl dealers, with some customers reporting that new caps have made a huge difference.

How to replace a Stihl gas cap if it's swollen from reacting to gas

If your Stihl gas cap has swollen from reacting to gas, you can replace it by following these steps:

• Discontinue use of the product immediately.
• Take your product to an authorized Stihl dealer.
• Have them install a new toolless fuel cap, which will be done free of charge.

Alternatively, you can purchase a new gas cap for around $10 from a Stihl dealer. If you choose to do this, make sure to follow the instructions provided with the new cap for attaching the cap string.

It is important to note that Stihl has recalled certain products with toolless fuel caps due to safety concerns. The levels of ethanol, aromatics, or other additives in some gasoline may distort parts of the fuel cap, making it difficult to install and/or remove. This could lead to fuel spillage and a potential fire hazard.

Where to attach the cap string on a Stihl gas cap

The Stihl gas cap has a cord with a small plastic ball at the end. This ball should be attached to the inside of the gas tank. There is a small moulding inside the tank, and the ball should fit into a slot near the opening. This slot is best identified as slot #2 in the service manual for 1998 and newer Stihl saws.

To attach the cap string, squeeze the ends of the T-shaped moulding and stick it into the tank. If the moulding has a round ball at the end, it may be attached to the fuel filter.

If you are still unsure about where to attach the cap string, consult your Stihl dealer or a Stihl service manual.

How to remove the OEM gas cap from a Stihl MS271

To remove the OEM gas cap from a Stihl MS271, you will need to locate the ball at the end of the string attached to the cap. Push this ball down into the tank, and then push the cord attached to the ball straight down. This will release the cap from its retainer.

It is important to note that if you are removing the gas cap because it has been affected by the recall, you should discontinue use of your Stihl product immediately and take it to an authorized Stihl dealer. The dealer will install a new toolless fuel cap at no cost to you.

The recall affects certain Stihl products with toolless fuel caps, which were sold throughout the United States by Stihl dealers. The levels of ethanol, aromatics, or other additives in some gasoline sold in the United States may distort parts of the fuel cap, making it difficult to install and/or remove. If the fuel cap is not properly installed, fuel spillage could occur, creating a risk of fire if an ignition source is present.

The toolless fuel caps that are being recalled can be distinguished from the newly designed caps by a molded identifier mark located on the lever of the cap and a letter molded on the underside of the cap.

How to replace a Stihl gas cap if it's causing chafing

If your Stihl gas cap is causing chafing, it may be time to replace it. Here's a step-by-step guide on how to do it:

Step 1: Inspect the Gas Cap

Before rushing to replace the gas cap, it's important to inspect it thoroughly to identify any issues. Check for any signs of damage, such as cracks or leaks, which could be causing the chafing. If the gas cap shows signs of swelling, it may be due to a reaction between the plastic and the gas. This issue was common in certain Stihl products and was addressed in a warranty recall.

Step 2: Discontinue Use and Contact Your Dealer

If you suspect that your Stihl product is part of the recall, it is important to discontinue use immediately. Take your product to an authorized Stihl dealer, who can assess the issue and provide a suitable solution. In some cases, they may install a new toolless fuel cap at no cost to you.

Step 3: Identify the Correct Replacement Cap

When replacing the gas cap, it is crucial to use an appropriate replacement. Ensure that the new cap is compatible with your specific Stihl model. You can refer to the model numbers provided in the recall notice or consult with your Stihl dealer to identify the correct replacement cap.

Step 4: Purchase a New Gas Cap

If your product is not part of the recall or if the warranty period has expired, you may need to purchase a new gas cap. You can buy replacement caps from authorized Stihl dealers or online retailers. It is recommended to have a few spare caps on hand, as gas caps can fail unexpectedly.

Step 5: Install the New Gas Cap

Once you have obtained the correct replacement cap, carefully install it onto your Stihl product. Ensure that the cap is properly aligned and locked into place. Refer to your product's manual for specific instructions on how to install the gas cap correctly.

By following these steps, you can effectively replace your Stihl gas cap if it is causing chafing. Remember to exercise caution when handling gasoline and always prioritize your safety.

How to distinguish a recalled Stihl fuel cap from a new one

If you own a Stihl product and are concerned about the fuel cap, there are a few things you should know. Firstly, Stihl has issued a recall for certain yard power tools with toolless fuel caps due to safety concerns. This recall affects products sold throughout the United States by Stihl Dealers.

The specific issue is that the levels of ethanol, aromatics, or other additives in some gasoline sold in the United States may distort parts of the fuel cap, making it difficult to install and/or remove. This can lead to fuel spillage, which poses a fire hazard if an ignition source is present. It is important to note that Stihl has received no reports of injuries related to this issue.

To distinguish a recalled fuel cap from a new one, you can look for two identifying marks. Firstly, there should be a molded identifier mark located on the lever of the cap. Secondly, there should be a letter molded on the underside of the cap. These markings indicate that the cap is a newly designed one that corrects the problem.

If you find that your Stihl product has a recalled fuel cap, you should discontinue use immediately and take it to an authorized Stihl Dealer. They will install a new toolless fuel cap for you at no cost. You can locate your nearest Stihl Dealer by using the Dealer Locator on the Stihl website or by calling their Customer Service number: 1-800-GO-STIHL.

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