Stihl Toolless Fuel Cap fire and burn hazard recall (CPSC May 25, 2011)

## Affected machines This is one of the largest Stihl recalls in CPSC history: approximately **2.3 million units** across 16 product lines, sold at authorized Stihl dealers nationwide from **July 2002 through May 2011** for between $190 and $650. The recall is **fuel-cap-specific** rather than model-specific - any unit in the listed product lines with a serial number at or below the cutoff and a toolless fuel cap of the original (pre-recall) design is in scope. Stihl revised the cap design to fix the problem; replacement caps have a molded identifier mark on the lever and a letter molded on the underside. ### Affected product lines and serial-number cutoffs **Backpack blowers** (up to SN 284053456): - BR 500 - BR 550 - BR 600 - BR 600 Magnum **Hedge trimmers** (up to SN 284101483): - HL 90K - HL 100 - HL 100K **Pole pruners**: - HT 56 C-E (up to 284398635) - HT 100, HT 101, HT 130, HT 131 (up to 284097165) **Edgers**: - FC 56 C-E, FC 70 C-E (up to 284180999) - FC 90, FC 95, FC 100, FC 110 (up to 284012099) **Trimmers / brushcutters**: - FS 40 C-E, FS 56 C-E, FS 56 RC-E, FS 70 RC-E (up to 284180999) - FS 90, FS 90 R, FS 100 RX, FS 110, FS 110 R, FS 110 RX, FS 130, FS 130 R (up to 284012099) **KombiMotors**: - KM 56 RC-E (up to 284180999) - KM 90 R, KM 110 R, KM 130 R (up to 284012099) Clearing saws sold during the same window are also included by the CPSC notice but are outside the consumer-equipment scope of the TractorNuity library. ## Issue The levels of **ethanol, aromatics, and other fuel additives** in some U.S. gasoline can distort the toolless fuel cap, making it difficult to install or remove. If the cap is not properly seated, fuel can spill out of the tank, posing a fire and burn hazard if an ignition source is present. Reported field incidents at time of recall: - 81 reports of difficulty installing/removing fuel caps and fuel spillage - 0 injuries ## What to do 1. Identify the model on the engine cover or starter housing. 2. Check the unit's serial number against the cutoffs above. 3. Inspect the fuel cap lever for the molded identifier mark added to the corrected design. Stihl's recall page provides photos for comparison: https://www.stihlusa.com/safety/recalls/toolless-fuel-cap/ 4. If the unit is in scope and has the original cap, **stop using it immediately**. 5. Take it to an authorized Stihl dealer for free replacement of the toolless fuel cap. 6. Contact Stihl Inc. toll-free at (800) 233-4729 or email stihlrecall@stihl.us with questions. ## Hazard Severity is rated **critical** because of the fire and burn risk from fuel spillage onto a hot engine - consistent with how other fuel-leak fire-hazard bulletins are rated in the TractorNuity library (TNB02600076 Briggs/Ariens, TNB02600080 Stihl MS 461, TNB02600107 Stihl Gasoline Tank Vent, etc.). The recall remains active. Stihl has noted that some dealers and consumers may not be aware the recall is still in effect; replacement caps remain available free of charge for affected units. ## Related bulletins This is the largest Stihl recall by unit count in the library. Related Stihl fuel-system fire-hazard bulletins: - TNB02600080 (MS 461 chainsaw fuel-line pinch) - TNB02600107 (Gasoline Tank Vent - the FC 56 C / FS 40-56 C / HT 56 C / KM 56 RC successor recall, March 2016) - TNB02600111 (TS 480i / TS 500i fuel-line crack) The BR 500 Exhaust Deflector service action (TNB02600116) covers a separate exhaust-deflector service for the same BR 500 model that appears in this recall. ## Source - U.S. Consumer Product Safety Commission, "STIHL Recalls Yard Power Products Due to Burn and Fire Hazards," recall announcement, May 25, 2011. - Stihl Toolless Fuel Cap recall page: https://www.stihlusa.com/safety/recalls/toolless-fuel-cap/