STIHL 009 Chainsaw Repair Manual Free Download
The STIHL 009 is a lightweight, professional-grade chainsaw known for its reliability and power-to-weight ratio. This comprehensive repair manual covers safety procedures, technical specifications, troubleshooting, step-by-step repair instructions for the engine, fuel system, ignition, chain brake, bar, and chain, along with maintenance schedules and exploded parts diagrams. Below are key sections for safe operation, features, disassembly, repair procedures, and parts identification.
Safety Information & Warnings
Essential safety precautions to prevent serious injury or death when repairing the STIHL 009 chainsaw.
| Hazard | Precaution |
|---|
| Fuel & Fire | Work in well-ventilated area away from sparks or flames. Drain fuel tank before disassembly. |
| Sharp Components | Wear cut-resistant gloves when handling chain, bar, or sprocket. |
| Spring Tension | Chain brake and starter springs are under high tension. Use proper tools and eye protection. |
| Hot Surfaces | Allow engine and muffler to cool completely before beginning work. |
| Electrical Shock | Disconnect spark plug wire and secure away from plug during repair. |
WARNING! Failure to follow safety instructions can result in severe injury. Always refer to the manual.
Technical Specifications
- Model: STIHL 009
- Engine Type: Single cylinder, two-stroke, air-cooled
- Displacement: 31.8 cc (1.94 cu. in.)
- Power Output: 1.4 kW (1.9 hp)
- Fuel/Oil Ratio: 50:1 (STIHL HP Ultra or equivalent)
- Ignition System: Electronic, flywheel magneto
- Carburetor: Zama C1Q-S series
- Chain Pitch: 3/8" PMM or .325"
- Bar Lengths: 12" to 16" (30 cm to 40 cm)
- Weight (powerhead): Approximately 4.2 kg (9.3 lbs)
Tools Required
Standard and specialty tools needed for complete repair.
- STIHL combination wrench or socket set (13mm, 8mm)
- Torx screwdrivers (T27, T10)
- Feeler gauge set (0.10mm, 0.15mm, 0.20mm)
- Compression tester
- Spark plug wrench
- Piston stop tool
- Clutch holding tool (STIHL 0000 893 4300 or equivalent)
- Chain brake spring compressor
- Carburetor adjustment screwdriver
- Clean workspace with vise and soft jaws
Troubleshooting Guide
| Symptom | Possible Cause | Corrective Action |
|---|
| Engine won't start | No spark, flooded carb, fuel issue | Check spark plug, ignition coil gap (0.15mm), clean carburetor, ensure fresh fuel mix. |
| Engine starts then dies | Fuel filter clogged, air leak, faulty carb | Replace fuel filter, pressure test crankcase, rebuild carburetor. |
| Loss of power | Clogged spark arrestor, low compression | Clean muffler screen, test compression (should be >120 psi), inspect piston/cylinder. |
| Chain won't turn | Clutch worn, sprocket damaged, brake engaged | Inspect clutch shoes & drum, replace rim sprocket, disengage chain brake. |
| Excessive vibration | Unbalanced flywheel, loose components | Check flywheel key, tighten all bolts/mounts, inspect anti-vibration buffers. |
| Oil not feeding to bar | Clogged oil passages, faulty pump | Clean oil ports, check oil pump drive gear, replace oil line if cracked. |
Engine Repair & Rebuild
Step-by-step cylinder and piston service.
- Remove Cylinder: Remove muffler, intake, and cylinder cover bolts. Gently tap cylinder to break gasket seal.
- Inspect Piston & Cylinder: Look for scoring, aluminum transfer, or ring wear. Light scoring can be honed; deep damage requires replacement.
- Piston Ring Replacement: Compress rings with ring expander, align ring ends with piston pin locators.
- Crankcase Seals: Check for leaks. Pry out old seals with seal puller, press new seals flush using appropriate socket.
- Reassembly: Lubricate piston & rings with 2-stroke oil. Use new gaskets. Torque cylinder bolts to 10 Nm (88 in-lbs) in crisscross pattern.
CAUTION! Mark all components for orientation. Do not force parts during disassembly.
Fuel System & Carburetor
Zama C1Q-S carburetor adjustment and rebuild.
- Remove Carburetor: Disconnect fuel line, throttle linkage, and intake boot.
- Disassembly: Remove diaphragm covers, inspect pump and metering diaphragms for stiffness or holes.
- Clean: Soak metal parts in carb cleaner. Use compressed air to blow out all passages. Do not soak plastic or rubber parts.
- Adjustment Screws (Initial Settings): L screw: 1 turn open. H screw: 1 turn open. Idle speed screw: lightly seated then 1/2 turn open.
- Pressure & Vacuum Test: Use pump to test for leaks after reassembly.
Tip: Always use a carburetor rebuild kit with new gaskets, diaphragms, and needle valve.
Ignition System
Testing and replacing ignition components.
- Spark Plug: BPMR7A (NGK) or equivalent. Gap: 0.5mm (0.020"). Replace if electrode is worn or fouled.
- Ignition Coil: Check primary resistance (~1-2 Ω) and secondary resistance (~8-15 kΩ). Air gap between coil legs and flywheel magnets: 0.15mm (0.006"). Adjust with feeler gauge.
- Flywheel: Remove with puller. Inspect key for shearing. Clean magnet surfaces.
- Stop Switch: Test for continuity. Wire should break circuit when switch is pressed.
Chain Brake & Clutch
Service procedures for the manual chain brake and centrifugal clutch.
- Chain Brake Disassembly: Remove side cover, brake band, and handle. CAUTION: Brake spring is under high tension. Use compressor tool.
- Clutch Removal: Use clutch holding tool to prevent rotation. Turn clutch nut clockwise (left-hand threads) to remove.
- Inspection: Check clutch shoes for wear and drum for scoring. Replace if worn beyond service limits.
- Reassembly: Lubricate clutch bearing with high-temperature grease. Torque clutch nut to 40 Nm (30 ft-lbs).
Bar, Chain & Sprocket
Maintenance and replacement guide for cutting components.
- Bar Inspection: Check for straightness, rail wear, and sprocket nose rotation. Dress rails with flat file if uneven.
- Chain Sharpening: Use correct round file size (typically 4.0mm). Maintain 30° top plate angle and 10° down angle. Keep all cutters uniform length.
- Rim Sprocket: Replace when worn (teardrop shape). Ensure correct pitch (3/8" PMM or .325").
- Oil Flow Test: Run saw at high idle with bar tip near cardboard. A fine line of oil should appear.
Maintenance Schedule
| Interval | Task |
|---|
| Daily | Clean air filter, check chain tension, inspect for loose fasteners. |
| Every 20 Hours | Clean spark arrestor screen, sharpen chain, check clutch drum. |
| Every 50 Hours | Replace fuel filter, clean carburetor exterior, inspect fuel lines. |
| Every 100 Hours | Replace spark plug, clean cylinder fins, check crankcase seals. |
| Annually | Pressure/vacuum test engine, replace impulse line, full carb rebuild. |
Exploded Parts Diagrams
Reference diagrams for part numbers and assembly order. Common replacement parts include:
- Cylinder Kit: 1120 020 1205
- Piston Kit: 1120 030 2001
- Carburetor Kit: 1120 007 1060
- Ignition Coil: 1120 400 1303
- Clutch Assembly: 1120 160 2001
- Chain Brake Band: 1120 650 7701
- Fuel Line: 1128 358 7700
- Oil Pump: 1120 647 0800
Note: Part numbers may vary by serial number. Always verify with your specific saw or dealer.
Support: For genuine STIHL parts and technical assistance, contact an authorized STIHL dealer or visit www.stihlusa.com.
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