STIHL Chainsaw Workshop Manual Download

The STIHL Chainsaw Workshop Manual provides comprehensive technical information for servicing, maintaining, and repairing STIHL chainsaw models. It includes detailed instructions on engine overhaul, fuel system, ignition system, chain and bar maintenance, troubleshooting procedures, safety precautions, and parts diagrams. This manual is essential for professional technicians and experienced users. Below are key sections covering safety, specifications, maintenance procedures, troubleshooting, and parts information.

1. Safety Precautions 2. General Specifications 3. Maintenance Schedule 4. Engine Service 5. Fuel System 6. Ignition System 7. Chain & Bar Assembly 8. Troubleshooting Guide 9. Parts Diagrams 10. Torque Specifications 11. Warranty & Support

Safety Precautions

Essential safety guidelines for operating and servicing STIHL chainsaws.

Hazard	Precaution
Fuel handling	Use approved containers; refuel in well-ventilated area away from ignition sources
Chain operation	Always engage chain brake when not cutting; wear protective gloves and eyewear
Hot surfaces	Allow engine to cool before servicing muffler or cylinder
Electrical	Disconnect spark plug wire before performing any maintenance
Sharp edges	Handle cutting chain with extreme care; use proper tools
Lifting	Lift saw properly using handle; avoid back strain
Chemical exposure	Wear gloves when handling bar oil or fuel mixtures
Noise	Wear hearing protection during operation
Vibration	Take regular breaks to prevent white finger syndrome
Kickback	Maintain proper chain tension and sharpness; use reduced-kickback chain

General Specifications

Technical specifications for common STIHL chainsaw models.

Engine Type: 2-stroke, single cylinder, air-cooled.
Displacement: Ranges from 30.1cc to 91.1cc depending on model.
Power Output: 1.8 kW to 6.4 kW.
Fuel: Gasoline/oil mixture (50:1 for most models).
Ignition: Electronic, capacitor discharge.
Chain Pitch: 1/4", .325", 3/8", or .404".
Bar Length: 12" to 36" options.
Weight: 4.4 lbs to 20.7 lbs (powerhead only).
Sound Pressure: 106-115 dB(A) at operator's ear.
Vibration: Front/rear handle: 4.5-10 m/s².

Maintenance Schedule

Recommended maintenance intervals for optimal performance.

Daily: Check chain tension, sharpness, and lubrication; inspect air filter; check for loose fasteners.
Weekly: Clean spark arrestor screen; check fuel filter; inspect anti-vibration elements.
Monthly: Clean cooling fins; check spark plug condition and gap; inspect clutch and sprocket.
Seasonally: Replace fuel filter; clean carburetor; check ignition system; replace bar and chain if worn.
Annually: Compression test; decarbonize exhaust port; replace all filters; professional tune-up.

WARNING! Always use genuine STIHL parts for replacement. Improper maintenance voids warranty.

Engine Service

Procedures for engine disassembly, inspection, and reassembly.

Cylinder & Piston: Remove muffler; inspect cylinder scoring; measure piston clearance.
Crankshaft: Check bearings for play; inspect seals for leaks.
Connecting Rod: Measure small end bushing wear; check for straightness.
Compression Test: Minimum 110 psi for proper operation.
Reassembly: Use new gaskets; apply sealant to crankcase halves; torque fasteners to specification.

CAUTION! Mark all components during disassembly for proper reassembly orientation.

Fuel System

Carburetor adjustment and fuel delivery system maintenance.

Component	Service Procedure
Carburetor	Clean jets with compressed air; adjust H, L, and idle screws per specification
Fuel Filter	Replace annually or when clogged; use STIHL part number 0000 350 3500
Fuel Lines	Inspect for cracks; replace if hardened or leaking
Fuel Tank Vent	Clean with wire; ensure proper airflow
Primer Bulb	Check for cracks; replace if not holding prime

Tip: Use only fresh fuel (max 30 days old) with STIHL HP Ultra oil at 50:1 ratio.

Ignition System

Testing and replacement of ignition components.

Spark Plug: Gap 0.020" (0.5mm); replace annually or every 100 hours.
Ignition Module: Test with multimeter; resistance values in manual.
Stop Switch: Check continuity; replace if circuit remains open when engaged.
Flywheel: Check keyway; ensure proper torque (40-50 Nm).
Air Gap: Set between flywheel and coil (0.3-0.4mm).

WARNING! Never crank engine with spark plug removed and wire disconnected - risk of ignition module damage.

Chain & Bar Assembly

Maintenance and replacement of cutting components.

Chain Tension: Adjust so chain snaps back when pulled from bar.
Sharpening: Maintain 30° cutting angle; depth gauges at 0.025".
Bar Maintenance: File rails square; rotate bar weekly; clean oil holes.
Sprocket: Replace when worn by 0.5mm; use matching pitch.
Oil Pump: Adjust flow rate; test output (approx. 1 drop per second at idle).

CAUTION! Always stop engine and engage chain brake before servicing cutting attachments.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, flooded, fuel issue	Check spark; dry plug; verify fuel delivery; adjust carburetor
Engine runs poorly	Dirty air filter, clogged fuel filter	Clean/replace filters; check fuel lines
Chain won't turn	Clutch worn, sprocket damaged	Inspect clutch springs; replace sprocket
Excessive vibration	Loose components, unbalanced chain	Tighten all fasteners; balance chain
Overheating	Dirty cooling fins, lean mixture	Clean fins; adjust carburetor richer
Oil leakage	Seals damaged, overfilled	Replace crank seals; drain excess oil
Loss of power	Compression low, exhaust blocked	Test compression; clean spark arrestor
Chain won't oil	Clogged oil passages, pump failure	Clean bar oil holes; check pump operation

Parts Diagrams

Exploded views available for:

Cylinder and piston assembly
Crankshaft and bearing assembly
Carburetor and fuel system
Ignition system components
Clutch and chain brake assembly
Handle and anti-vibration system
Bar and chain combinations
Complete saw assembly

Note: Refer to specific model diagrams using STIHL part numbers.

Torque Specifications

Critical fastener torque values (Nm):

Component	Torque (Nm)	Thread Size
Cylinder bolts	10-12	M6
Crankcase screws	8-10	M5
Flywheel nut	40-50	M10
Clutch nut	35-40	M10
Spark plug	20-25	M14
Bar nuts	9-11	M8
Handle bolts	8-10	M6

WARNING! Use calibrated torque wrench; overtightening can damage components.

Warranty & Support

STIHL limited warranty: 1 year commercial use, 2 year residential use from date of purchase. Warranty covers defects in materials and workmanship. Not covered: normal wear, misuse, improper maintenance, non-STIHL parts.

Technical Support: Contact authorized STIHL servicing dealer. For dealer locator and manual downloads: www.stihlusa.com

Customer Service: 1-800-467-8445 (Monday-Friday 8am-8pm EST)

Safety Training: Available through STIHL dealers; recommended annually.