Older Stihl Manual

The Older Stihl Manual provides comprehensive guidance for operating, maintaining, and troubleshooting various older Stihl chainsaw models. It covers essential safety procedures, technical specifications, routine maintenance schedules, fuel and oil mixtures, chain sharpening techniques, and common troubleshooting steps for reliable performance. Below are key sections for safety, features, operation, maintenance, and troubleshooting.

Safety Guidelines

Essential safety components: Chain brake, throttle lockout, front and rear hand guards, spark arrestor muffler, anti-vibration system.

Safety Feature	Description
Chain Brake	Stops chain rotation instantly upon kickback or manual activation
Throttle Lockout	Prevents accidental throttle engagement
Front Hand Guard	Protects left hand from debris and chain contact
Rear Hand Guard	Shields right hand during operation
Spark Arrestor Muffler	Reduces fire risk by containing sparks
Anti-Vibration System	Minimizes operator fatigue and improves control
Chain Catcher	Traps broken chain to prevent injury
Right-Hand Guard	Additional protection for right-hand grip area
Debris Deflector	Directs wood chips away from operator
Stop Switch	Immediately cuts engine ignition

Model Overview & Features

Unpack and inspect all components. Verify model number matches manual.

1. Identify model: Check label on rear handle or engine housing.
2. Inspect components: Ensure chain, bar, spark plug, and tools are present.
3. Review safety decals: Understand all warning labels before operation.
4. Prepare work area: Clear debris and ensure stable footing.

WARNING! Always wear personal protective equipment: helmet, eye protection, hearing protection, gloves, chainsaw chaps, and steel-toe boots.

Assembly & First-Time Setup

Assemble chainsaw following step-by-step instructions.

1. Attach guide bar: Align bar with sprocket, tension chain appropriately.
2. Install chain: Ensure cutting teeth face forward on top of bar.
3. Add fuel mixture: Use correct gasoline/oil ratio (typically 50:1).
4. Prime and start: Engage choke, pull starter cord until engine fires.
5. Adjust chain tension: Chain should snap back when pulled from bar.

CAUTION! Never operate with loose chain or improper tension. Check all fasteners before each use.

Technical Specifications

• Engine Type: 2-stroke air-cooled gasoline engine.
• Displacement: Varies by model (typically 30-60cc).
• Power Output: 1.5-4.0 kW depending on model.
• Fuel Capacity: 0.5-0.9 liters.
• Oil Capacity: 0.2-0.3 liters.
• Guide Bar Length: 12-20 inches standard.
• Chain Pitch: 3/8" or .325" typical.
• Weight: 4.0-6.5 kg without bar and chain.
• Ignition System: Electronic, capacitor discharge.
• Idle Speed: 2,500-3,000 RPM.

Controls & Operation

Master controls before cutting. Front Handle: Contains throttle trigger and throttle lockout. Rear Handle: Houses stop switch, choke control, and primer bulb.

Starting Procedure: 1. Engage chain brake. 2. Set choke to cold start position. 3. Press primer bulb 5-10 times. 4. Pull starter cord until engine fires. 5. Disengage choke. 6. Squeeze throttle to idle.

Cutting Techniques: Use lower quadrant of bar for cutting. Maintain firm grip with both hands. Never cut above shoulder height. Be aware of kickback zone (upper quadrant of bar tip).

Fuel & Lubrication

Use fresh unleaded gasoline (minimum 89 octane) mixed with high-quality 2-stroke oil.

1. Mixing ratio: 50:1 (20ml oil per 1 liter gasoline) for most older models.
2. Mix thoroughly in separate container before fueling.
3. Fill fuel tank to 80% capacity to allow for expansion.
4. Use Stihl chain oil or equivalent for bar and chain lubrication.
5. Check oiler function before each use.

Tip: Never use automotive motor oil or fuel older than 30 days. Store fuel in approved containers.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Daily: Clean air filter, check chain tension, inspect bar for wear.
2. Weekly: Clean spark arrestor screen, check spark plug condition.
3. Monthly: Clean cooling fins, check fuel filter, inspect anti-vibration elements.
4. Seasonally: Replace fuel filter, clean carburetor, check clutch drum.
5. Annually: Replace spark plug, check cylinder compression, inspect all safety features.

WARNING! Always disconnect spark plug wire before performing maintenance. Allow engine to cool completely.

Chain Care & Sharpening

Sharp chain improves cutting efficiency and reduces operator fatigue.

1. File size: Match to chain specifications (typically 5/32" or 3/16").
2. Filing angle: Maintain 30° cutting angle for most chains.
3. Depth gauges: File to 0.025" below cutter height.
4. Filing direction: Always file from inside to outside of cutter.
5. Equal strokes: Apply same number of strokes to each cutter.
6. Chain rotation: Rotate chain regularly to ensure even wear.
7. Bar maintenance: File bar rails flat, clean oil holes weekly.

CAUTION! Wear gloves when handling chain. Secure bar in vise during sharpening.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

1. Empty fuel tank or add fuel stabilizer.
2. Run engine until carburetor is dry.
3. Remove chain, clean and oil thoroughly.
4. Clean entire saw, especially cooling fins and air filter.
5. Store in dry location, protected from moisture and temperature extremes.
6. Hang by rear handle or store on flat surface.

Long-term storage: Remove spark plug, add teaspoon of oil to cylinder, pull starter cord slowly to distribute oil.

Warranty & Support

Original warranty periods vary by model and purchase date. Most older Stihl models carried a 1-year commercial or 2-year residential warranty from date of purchase. Proof of purchase required for warranty claims. For support with older models, contact authorized Stihl servicing dealers. Genuine Stihl parts recommended for all repairs. For technical assistance, visit www.stihlusa.com or contact customer service at 1-800-467-8445.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Old fuel, clogged filter, fouled spark plug	Use fresh fuel mix, replace fuel filter, clean/replace spark plug.
Engine starts then dies	Clogged carburetor, air leak, faulty ignition	Clean carburetor, check seals and gaskets, test ignition coil.
Poor cutting performance	Dull chain, improper tension, worn bar	Sharpen chain, adjust tension, replace worn bar.
Excessive vibration	Loose components, worn anti-vibration elements	Tighten all fasteners, replace anti-vibration buffers.
Chain doesn't oil	Clogged oiler, empty oil tank, worn pump	Clean oil passages, fill oil tank, replace oil pump.
Overheating	Dirty cooling fins, lean fuel mixture	Clean cooling fins, adjust carburetor, check fuel lines.
Loss of power	Clogged exhaust, worn piston/cylinder	Clean spark arrestor, check compression, rebuild if needed.

Professional Service: For complex repairs, consult authorized Stihl dealer. Never modify safety features or operate with damaged components.

Service Network: 1-800-467-8445; www.stihlusa.com