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6 Common Troy-Bilt Chainsaw Problems (Troubleshoot)

Maintaining your chainsaw by performing routine checks and servicing can help catch small problems before they become bigger ones.

Not only can routine maintenance help catch problems, but it will also keep your chainsaw performing at its best by running clean filters, fresh fuel, and a good spark plug.

I’ve put together this guide to help you determine the cause of your Troy-Bilt chainsaw problem. Here you can find simple charts with causes and solutions. I’ve also provided links to articles in more detail to further help.

Always follow the safety precautions found in your Troy-Bilt operator’s manual. This includes waiting for the engine to cool and for all parts to stop moving and removing the spark plug wire before performing repairs.

Common Troy-Bilt Chainsaw Problems

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Follow all safety instructions provided in your equipment operator’s manual before diagnosing, repairing, or operating. Consult a professional if you don’t have the skills, or knowledge or are not in the condition to perform the repair safely.

Common Troy-Bilt Chainsaw Problems & Solutions

1. Chainsaw Won’t Start

Begin looking for a starting problem by checking items that can keep the engine from getting sufficient air, fuel, and spark required to start the engine.

Make sure you are using the correct gas-to-oil fuel mixture at a ratio of 40:1. Always use fresh fuel with a minimum 89-octane rating and maximum 10% ethanol content.

Mix the gas with a premium 2-cycle engine oil like this oil from MTD. This gas and oil mixture should be consumed within 30 days.

Adding a fuel stabilizer like Sea Foam to fresh fuel will help make it last a little longer. Some 2-cycle oils also include a stabilizer.

Detailed information can be found at:
Reasons Your Troy-Bilt Chainsaw Won’t Start

CauseReason for the ProblemSolution
Bad or old fuelFuel breaks down over time making the fuel less efficient and prone to clogging the fuel system.Drain the fuel tank and fill it with fresh gas and 2-cycle oil. mix at a ratio of 40:1. Use a fuel additive like Sea Foam to stabilize the fuel and assist with cleaning the fuel system. Use the right fuel.
Incorrect 2-cycle oil mixAn incorrect mix can fail to provide the lubrication the engine requires.Mix gas and 2-cycle oil at a rate of 40:1. Use gas with a minimum 89-octane rating and maximum 10% ethanol content.
Bad spark plugA dirty or damaged spark plug; loose spark plug wire, or incorrect gap can prevent the engine from starting. Replace with a new spark plug, secure connections, and ensure it is gapped to manufacturer specifications.
Plugged air filterDirt can plug the air filter preventing airflowRemove the filter and clean it. Replace the filter if it is in bad condition.
Plugged fuel filterA dirty fuel filter will restrict fuel flow.Replace the fuel filter.
Blocked fuel linesDeposits left behind by old fuel and dirt can clog the fuel lines preventing the engine from getting fuel.Use a carburetor cleaner and compressed air to clear the clog out of the fuel line. Replace the line if necessary.
Plugged fuel tank ventA plugged fuel tank vent will no longer allow the tank to vent. A vacuum will form keeping fuel from flowing out of the tank.Replace a plugged fuel tank vent.
Plugged spark arrestorHot air isn’t able to exit the chainsaw when the spark arrestor is plugged with soot.Remove and clean the spark arrestor screen.
Dirty carburetorThe carburetor can become dirty and clogged due to bad fuel and ethanol deposits preventing fuel flow.Clean the components making up the carburetor. Replace it if needed.
Bad primer bulbA cracked primer bulb will fail to move fuel to the carburetor.Replace the primer bulb
Flooded engineThe fuel-to-air mixture is running too rich that it can’t ignite. This can be caused by pressing the primer bulb too many times or pulling the starter rope too many times while the choke is closed.Fix using the method provided in this article.
Broken starter recoilA damaged or broken recoil prevents the recoil to start the engine.Check the recoil to see if it can be restrung. Broken parts must be replaced. Replace the recoil assembly if needed.
Troy-Bilt Chainsaw Starting Problems

2. Chainsaw Starts, Stalls & Dies

Many of the items that can cause a Troy-Bilt starting problem are also reasons that can cause it to stall and die after running.

Make sure you have adjusted the choke to the open position after the engine has warmed or it will begin to run sluggishly and die due to a lack of air.

If your chainsaw dies after it’s been running awhile and won’t start again until you allow air to enter the fuel tank, you may have a fuel tank vent problem.

Detailed information can be found at:
Your Troy-Bilt Chainsaw Starts, Stalls and Dies

CauseReason for the ProblemSolution
Wrong choke settingThe engine will die when the choke lever isn’t placed in the open position after the engine warms.Close the choke to restrict air to start a cold engine. Open it once the engine warms.
Bad fuelFuel breaks down over time making your fuel less efficient and prone to clogging the fuel system and engine damage.Drain the fuel tank and fill it with fresh fuel and 2-cycle engine oil mixed at a ratio of 40:1. Use a good fuel additive to assist with keeping the fuel stable and cleaning the fuel system.
Plugged air filterDirt can plug the air filter preventing airflow.Remove the filter and clean it. Replace the filter if it is in bad condition.
Plugged fuel filterA plugged fuel filter won’t allow sufficient gas to pass through it.Replace the fuel filter
Clogged fuel linesBad fuel deposits and dirt can build up and clog the fuel lines preventing the engine from getting the required fuel.Use a carburetor cleaner and compressed air to clear the clog out of the fuel line. Replace a bad fuel line.
Dirty carburetorThe carburetor can become dirty and clogged due to bad fuel and ethanol deposits preventing fuel flowClean all the components making up the carburetor. Rebuild or replace if needed.
Plugged fuel tank ventA plugged fuel tank vent will no longer allow the tank to vent. A vacuum will form keeping fuel from flowing out of the tank.Replace a plugged fuel tank vent.
Plugged spark arrestorThe spark arrestor can plug with soot so hot air can no longer exhaust.Remove the spark arrestor screen and clean it with a metal brush. Replace a damaged screen
Reasons a Troy-Bilt Chainsaw Starts, Stalls, and Dies

3. Chain Won’t Turn or Move

The chain may no longer move smoothly around the bar. First thing, never touch the chain without removing the spark plug wire for safety reasons.

Next, look for bar or chain damage or incorrect chain tension. Make sure the bar and chain are sufficiently lubricated, and check for worn clutch pads.

Detailed information can be found at:
Your Troy-Bilt Chainsaw Chain Won’t Move, Spin or Rotate

CauseReason for the ProblemSolution
Chain brake is engagedThe chain brake is a safety guard that reduces the possibility of injury in the event of a kickback by stopping the chain.Ensure the chain brake is pulled to the rear of the saw so the is not engaged.
Bar & chain are not sufficiently lubricatedA buildup of friction and heat due to insufficient lubrication can cause the chain to stop turning on the bar.Fill the bar and chain oil reservoir. Check the oil channel to make sure there isn’t a clog.
Chain tension is too tightThe chain should sit securely around the guide bar and still be able to move easily. The chain should not be hanging loose from the bar.Remove the spark plug wire. Adjust the chain by loosening the bar retaining nuts. Hold the bar nose up. Turn the tensioning screw counter-clockwise to loosen the chain and clockwise to tighten it.
Clutch pads are wornWorn clutch pads won’t engage the clutch drum to turn the chain.Replace the clutch assembly.
Reasons a Troy-Bilt Chainsaw Chain Won’t Move or Turn

4. Engine Runs With the Choke On

A Troy-Bilt chainsaw only runs with the choke on when the engine is getting too much air or not enough fuel.

The choke is engaged to correct the gas-to-air ratio required so the mixture ignites when the piston compresses it.

Detailed information can be found at:
Your Troy-Bilt Chainsaw Only Runs with the Choke On

CauseReason for the ProblemSolution
Old fuelOld fuel can leave behind varnish and deposits that cause fuel restrictions and fuel component failures.Drain the fuel tank. Refill with fresh gas and 2-cycle oil mixed at a ratio of 40:1. Add a fuel stabilizer and fuel system cleaner. Start and allow the fuel to work its way through the fuel system.
Fuel line punctureAir can be sucked into the line increasing the amount of air getting to the engine.Replace the fuel line. Check for fuel line restrictions.
Plugged fuel filterA dirty plugged air filter restricts airflow.Replace the air filter.
Bad carburetor gasketThe gasket may no longer seal allowing excess air into the carburetor.Remove the carburetor and replace the gasket.
Dirty carburetorFuel passages can clog and no longer allow sufficient gas for the combustion process.Remove and clean the carburetor. Rebuild or replace it if needed.
Plugged fuel tank ventA plugged fuel tank vent will cause a vacuum to form in the fuel tank. This will keep fuel from flowing out of the tank.Replace the fuel tank vent.
Reasons a Troy-Bilt Chainsaw Only Runs with the Choke On

5. Chainsaw Loses Power and Bogs Down

It is often a dirty carburetor that causes a Troy-Bilt chainsaw to lose power and bog down. Old gas clogs the fuel passageway.

Check for items that interfere with the air and fuel mix. You should also check the exhaust to make sure hot air can exit from the chainsaw.

Detailed information can be found at:
Reasons Troy-Bilt Chainsaw Loses Power & Bogs Down

CauseReason for the ProblemSolution
Old fuelOld fuel can leave behind varnish and deposits that cause fuel restrictions and fuel component failures.Drain the fuel tank. Refill with fresh gas and 2-cycle oil mixed at a ratio of 40:1. Add a fuel stabilizer and fuel system cleaner. Start and allow the fuel to work its way through the fuel system.
Plugged air filterGood airflow cannot pass through a plugged air filter.Replace the air filter.
Dirty spark plugA dirty spark plug can cause an intermittent spark.Clean or replace the spark plug.
Plugged fuel filterSufficient fuel is unable to pass through a plugged filter.Replace the fuel filter.
Clogged or punctured fuel lineClogged fuel lines can keep fuel from getting to the carburetor.Try to clean the fuel line or replace it.
Plugged fuel tank ventA plugged fuel tank vent will cause a vacuum to form in the fuel tank. This will keep fuel from flowing out of the tank.Replace the fuel tank.
Plugged spark arrestorThe spark arrestor can plug with soot so hot air can no longer exhaust.Remove the spark arrestor screen and clean it with a wire brush.
Chain brake is engagedThe chain brake is a safety device to stop the chain in the event of a kickback.Place the chain brake in the off position.
Dirty carburetorFuel passages can clog and no longer allow sufficient gas for the combustion process.Clean the carburetor to remove varnish left behind by old fuel. Rebuild or replace it if necessary.
Carburetor requires an adjustmentThe RPMs at idle speed and full throttle may need to be adjusted for good performance.Check out this guide for information on adjusting a Troy-Bilt chainsaw carburetor.
Reasons a Troy-Bilt Chainsaw Loses Power & Bogs Down

6. Chainsaw Is Smoking

When your Troy-Bilt chainsaw smokes when cutting, you need to look for items that can cause increased friction between the bar and chain.

You may experience smoke coming from the engine and exhaust. This may be due to a wrong fuel mixture, water in the fuel, or a plugged air filter.

Detailed information can be found at:
Reasons a Troy-Bilt Chainsaw Smokes

CauseReasons for the ProblemSolution
Dull chainMore pressure must be applied when using a dull or incorrectly sharpened chain. Pressure increases friction.Sharpen a dull chain. Have the chain professionally sharpened if you are unsure how to sharpen the chain for safe use.
Tight chainFriction and smoke occur when the chain isn’t able to move freely around the bar.Remove the spark plug wire and adjust the chain.
Empty bar & chain oil tankFriction builds when there is a lack of oil.Fill the tank with bar & chain oil.
Wrong bar & chain oilToo thin of oil will not sufficiently stick to the bar.Use a good oil like ECHO bar & chain oil.
Clogged oilerOil isn’t able to lubricate the bar and chain when the oiler is clogged.Clean the oiler.
Plugged air filterA plugged filter will cause the fuel mixture to run rich resulting in smoke.Replace a very dirty air filter. Check and clean it regularly.
Too much oil in the fuel mixtureMore oil than required in Troy-Bilt 40:1 fuel mix can cause the chainsaw to smoke.Drain the fuel and fill the tank with the correct 40:1 fuel mix.
Water in the fuel mixtureWater can create white exhaust smoke.Drain the fuel and fill the tank with fresh gas and oil at a 40:1 ratio.
Reasons a Troy-Bilt Chainsaw Smokes

Don’t Skip Maintenance on Your Troy-Bilt Chainsaw

Like other outdoor equipment you own, you will eventually experience a problem with your Troy-Bilt chainsaw.

Regularly maintaining your saw and always running fresh fuel through it will help reduce problems developing in the saw and increase its life expectancy.

I recommend completing a full maintenance service on your Troy-Bilt chainsaw once a year to keep it in good condition.

The annual service includes replacing the maintenance parts: air filter, fuel filter, and spark plug. You should also check the fuel system and cooling system, and clean the exterior.

Tighten any loose hardware and replace any damaged or missing parts. In addition, you must inspect the chain before each use to ensure it is in good condition.