Stihl 510 Chainsaw Manual

The Stihl 510 is a professional-grade chainsaw designed for demanding forestry and arborist work. It features a powerful engine, robust construction, advanced safety systems, and ergonomic design for extended use. Below are key sections for safety, features, assembly, operation, maintenance, troubleshooting, and specifications.

Features at a Glance

Key components: High-performance 2-stroke engine, QuickStop® inertia-activated chain brake, anti-vibration system, side-access chain tensioner, tool-free air filter cover, and decompression valve.

Feature	Description
Engine Displacement	50.2 cc professional engine
Power Output	High torque for demanding cuts
Guide Bar Lengths	Compatible with 16" to 20" bars
Safety Features	QuickStop® chain brake, front hand guard, throttle lockout
Anti-Vibration System	Reduces operator fatigue
Fuel System	Diaphragm carburetor with fuel pump
Ignition System	Electronic ignition (CDI)
Starter System	Easystart™ with decompression valve
Weight (without bar/chain)	Approximately 5.7 kg (12.6 lbs)
Chain Oil	Automatic oiler with adjustable flow

Safety Information

Read and understand all instructions before operation. Always wear appropriate PPE.

1. Personal Protective Equipment (PPE): Wear chainsaw chaps, safety glasses, hearing protection, helmet with face shield, and sturdy gloves.
2. Work Area Safety: Clear area of bystanders, especially children. Ensure secure footing.
3. Chain Brake: Test QuickStop® function before each use.
4. Kickback Awareness: Be aware of kickback zone; use reduced-kickback chain and bar.
5. Fuel Safety: Refuel in well-ventilated area, away from ignition sources. Use fuel/oil mix specified.

WARNING! Improper use can cause serious injury or death. Never operate a chainsaw alone.

Assembly & Preparation

Unpack and inspect contents. Assemble guide bar and chain.

1. Attach Guide Bar: Remove side cover, position bar on studs, ensure tensioning pin engages in bar hole.
2. Install Chain: Place chain over bar sprocket, ensuring cutting teeth face forward on top of bar.
3. Tension Chain: Use side tensioner to adjust until chain snaps back when pulled from bar.
4. Fill Fluids: Add recommended 2-stroke engine oil/fuel mix to fuel tank. Fill chain oil reservoir with bar and chain oil.
5. Check Controls: Ensure throttle trigger, throttle lockout, and chain brake function correctly.

CAUTION! Always wear protective gloves when handling the chain. Chain is extremely sharp.

Specifications

• Engine Type: Single cylinder, 2-stroke, air-cooled.
• Displacement: 50.2 cc.
• Power Output: 3.0 kW (4.0 hp).
• Fuel/Oil Mix Ratio: 50:1 (Stihl HP Ultra or equivalent).
• Fuel Tank Capacity: 0.55 L (18.6 fl oz).
• Chain Oil Tank Capacity: 0.33 L (11.2 fl oz).
• Idle Speed: 2,800 rpm.
• Maximum Power Speed: 9,500 rpm.
• Ignition: Electronic, capacitor discharge (CDI).
• Spark Plug: Bosch WSR 6 F or equivalent, gap 0.5 mm (0.020 in).
• Sound Pressure Level: 112 dB(A) (operator position).
• Vibration Levels: Left/Right handles: 4.5/5.5 m/s².

Controls and Components

Master Control Lever: Combines stop switch, choke, and fast idle functions. Front Handle: Includes throttle trigger and throttle lockout. Rear Handle: Contains master control lever and starter grip.

Key Controls: Master Control Lever (Stop/Choke/Run), Throttle Trigger, Throttle Lockout (safety), Chain Brake Lever (front hand guard), Decompression Valve, Chain Tensioner (side), Chain Oiler Adjustment Screw.

Safety Systems: QuickStop® chain brake (inertia-activated), front hand guard, right-hand guard, chain catch, and vibration damping.

Starting & Stopping Procedure

Cold Start:

1. Engage chain brake by pushing front hand guard forward.
2. Set Master Control Lever to choke position (full down).
3. Press decompression valve (if equipped).
4. Place saw on firm ground, hold rear handle with right foot.
5. Pull starter rope sharply until engine fires (usually 1-3 pulls).
6. Immediately move Master Control Lever to half-throttle (fast idle) position.
7. Pull starter rope again until engine starts.
8. Blip throttle to disengage fast idle. Saw is ready.

Warm Start: Master Control Lever in run position (horizontal). No choke needed.

Stopping: Release throttle, allow engine to idle. Move Master Control Lever to STOP (up) position.

Operation & Cutting Techniques

Always use proper stance and grip. Keep both hands on handles.

1. Felling: Plan escape path. Use notch and back cut technique. Never cut above shoulder height.
2. Limbing: Work from trunk outward. Support saw with trunk; beware of spring poles.
3. Bucking: Support log properly. Use top of bar for cutting; avoid contacting ground with chain.
4. Kickback Prevention: Do not cut with bar nose. Maintain firm grip, high RPM before contacting wood.
5. Chain Oiler: Adjust oil flow via screw for dusty conditions or large bars.

WARNING! Do not operate chainsaw in a tree unless specifically trained as a climber.

Maintenance Schedule

Interval	Task
Before each use	Check chain tension, sharpness, brake function, fluids.
Daily	Clean air filter, check for loose fasteners, clean saw exterior.
Weekly	Clean spark arrestor screen, inspect spark plug, check fuel filter.
Monthly	Clean cooling fins, inspect anti-vibration elements, check clutch drum and sprocket.
Annually	Professional inspection of piston, cylinder, carburetor adjustments.

Use only genuine Stihl parts and recommended lubricants.

Chain Sharpening & Tensioning

Sharp chain is essential for safety and performance.

1. Sharpening: Use correct round file size (typically 5.2 mm / 13/64"). Maintain 30° top plate angle and 10° file tilt. File all cutters to equal length.
2. Depth Gauges: Use flat file and gauge to lower depth gauges (rakers) to 0.65 mm (0.025") below cutter top plate.
3. Tensioning: Chain should be snug against bar but pull freely by hand. Re-tension when chain feels loose (check cold).
4. Bar Maintenance: Clean bar groove weekly. Flip bar monthly for even wear.

CAUTION! Always wear gloves. Secure bar in vise during sharpening.

Storage Guidelines

For storage over 30 days:

1. Drain fuel tank and run carburetor dry.
2. Remove chain, clean and soak in oil. Clean bar groove.
3. Clean entire saw, especially cooling fins and air filter.
4. Store in dry, cool place, away from ignition sources.
5. Remove spark plug, add a few drops of oil into cylinder, pull starter slowly to coat, reinstall plug.

Tip: Use fuel stabilizer if unable to drain fuel completely.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, fuel issues	Check spark plug, use correct starting procedure, ensure fresh fuel mix.
Engine starts then dies	Clogged air/fuel filter, carb adjustment	Clean/replace filters. May need carburetor adjustment by dealer.
Loss of power	Dirty air filter, clogged spark arrestor, dull chain	Clean air filter and spark arrestor screen. Sharpen chain.
Chain does not oil	Empty oil tank, clogged oil passages	Fill tank, clean oil outlet hole in bar, check oil pump.
Excessive vibration	Loose components, damaged AV mounts	Tighten all fasteners. Inspect anti-vibration elements.
Chain throws or comes off	Loose chain, worn bar, damaged drive sprocket	Tension chain properly. Inspect bar and sprocket for wear; replace if grooved.

Service: For major repairs, contact an authorized Stihl servicing dealer. Use only genuine Stihl parts.

Support: Stihl Incorporated, 1-800-467-8445, www.stihlusa.com