Chris-PA
Where the Wild Things Are
Interesting - I also bought two replacement caps. The first one failed in a similar way in a short time, only not quite as bad, but the second has held up well so far. I've tried to remember the timing but I'm not really sure, however I think the problem started before ethanol was really common. I do find it surprising that a fuel cap problem would be allowed to linger for so long, as that would seem to be the kind of thing they would be all over very quickly.We bought two spare caps and he has to rotate them to dry out so the swelling goes down and they are usable again.
The long story behind that is this - I called Poulan and they were quite rude and not helpful at all. Basically they said they would not send a new gas cap and I could buy another one or two and rotate them to let them dry out but it was not going to be any different, they have not changed the material despite knowing it doesn't work right for over 11 years - their words, not mine. I laid into them pretty good that they would keep using gas caps that they know darn well have big problems - safety problems from spilling gas because you can't close them properly half the time. There are threads out here about this issue.
By then I was speaking to a manager and explained to him that the flippy gas cap on my Stihl weed whacker wasn't right and before I even got to call the dealer I got a recall notice from Stihl and a hastle free replacement from the dealer and an apology from Stihl. I also explained how my Husqvarna dealer gladly swapped my bar/chain on my new saw after I brought it home when I decided I'd rather have the .325 narrow kerf. I asked how come they were so helpful, even when they didn't have to be, and Poulan service sucks. His response was, and I quote, "Well sir, this isn't Stihl or Husqvarna. Stihl and Husqvarna are different kinds of products than what we produce."
Now Poulan and Husqvarna are still owned by the same parent company I think but clearly very different products and different support. So there it is, straight from the horse's mouth (or maybe the other end), Poulan admits to being a second or third rate product compared to Stihl and Husqvarna. Now we all know this already but to have Poulan actually come right out and say it is pretty bad IMHO. Not to say that Poulan doesn't make an OK saw for the homeowner market and it's priced to reflect that it is not a Stihl or Husky, but I just can't believe they basically said, yeah we suck, sorry without at least trying to defend their products and service.
I wasn't even trying to say that Poulan should be as good as Husky or Stihl (or Dolmar, Solo, Efco, etc). I understand that they can't be for the price they sell Poulan saws for. I was just trying to get them to replace a clearly defective part that causes a potentially dangerous situation, not to mention the green people are gonna get mad from all the gas being spilled.
I used to store the saw in its side to keep the fuel off the cap, and that seemed to help.