Went to do some cutting today, and first pull told me it was toasted. Failed the drop test.
So, pulled the muffler, which fought like crazy, and found some weird yellow powder caked in the exhaust port. It FILLED the port completely. I picked most of it out with a screwdriver, and this is what it looks like:
The history is this:
This is a John Deere/Efco CS-52. I got it from an AS member (a couple of years ago) who modded (gutted) the muffler. It's been a champ so far. A few weeks ago, I changed the spark plug and cleaned the air filter after some heavy use. Spark plug looked good - nice light brown, evenly colored.
I found the muffler nuts had some loose, and the front half of the muffler had been rattling around, apparently for quite a while. I put it back together, using some star washers to hold it together better. The metal around one bolt had fatigued and cracked, opening up the hole a bit, so the wide star washer I used closed that up.
I've run about a tank and a half since then with no apparent problems. Last use was about a week ago. Went to use it today, and no joy.
When I pulled it apart, I found the back half of the muffler had also fatigued and broken:
This was hidden by a backing plate inside the muffler, so I didn't see it when I fixed the loose front half:
So, clearly I've had exhaust conditions for which the saw was not tuned, to say the least. (Where's the 'stupid' smiley here?)
I had expected to find smeared rings, but no, they just look collapsed. I see no smearing at all:
So, obvisouly I need to tear it down and rebuild it, but what in the world is this yellow stuff, and how did it get caked in the exhaust port?
And what, exactly, did I do wrong?