STIHL 009 Chainsaw Service Manual

The STIHL 009 is a lightweight, professional-grade chainsaw featuring a single-cylinder, two-stroke engine with electronic ignition, automatic oiling system, anti-vibration handles, and a quick-stop chain brake. This manual covers essential safety procedures, technical specifications, routine maintenance, troubleshooting, and repair instructions for the STIHL 009 model. Below are key sections for operation, maintenance, and service.

Safety Information

Essential safety precautions to prevent injury during operation and maintenance.

Hazard	Precaution
Kickback	Always hold saw firmly with both hands; use reduced-kickback chain and bar.
Chain Contact	Wear cut-resistant chaps, gloves, and safety boots; keep bystanders away.
Fuel Handling	Refuel in well-ventilated area with engine off and cool; use approved fuel mix.
Exhaust Fumes	Operate only in well-ventilated outdoor areas to avoid carbon monoxide poisoning.
Hot Surfaces	Avoid contact with muffler and cylinder during/after operation.
Falling Debris	Wear safety helmet, eye protection, and hearing protection.
Chain Brake	Test chain brake function before each use.
Maintenance	Disconnect spark plug wire before performing any maintenance.

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 Tank Capacity: 0.25 L (0.07 US gal)
• Oil Tank Capacity: 0.20 L (0.05 US gal)
• Guide Bar Lengths: 12" to 16" (30 cm to 40 cm)
• Chain Pitch: 3/8" PMM or 0.325"
• Ignition System: Electronic, non-adjustable
• Weight (powerhead only): 3.9 kg (8.6 lbs)
• Sound Pressure Level: 106 dB(A)
• Vibration Levels: Front handle: 4.5 m/s²; Rear handle: 6.5 m/s²

Components & Controls

Key parts and operator controls of the STIHL 009 chainsaw.

Component	Description
Front Handle	With integrated throttle trigger lockout and chain brake lever.
Rear Handle	Main grip with anti-vibration elements.
Throttle Trigger	Controls engine speed; must be unlocked with trigger lockout.
Chain Brake Lever	Manual activation; also activates automatically via inertia on kickback.
Master Control Lever	Combines stop switch, choke, and start throttle positions.
Fuel Tank Cap	Vented cap with integrated tank breather.
Oil Tank Cap	For chain and bar lubrication oil.
Decompression Valve	Reduces compression for easier starting (if equipped).
Spark Plug Boot	Connects to spark plug for ignition.
Muffler	With spark arrestor screen (must be cleaned regularly).

Assembly & First Use

Unpacking and preparing the chainsaw for initial operation.

1. Inspect Contents: Verify all parts are present and undamaged.
2. Attach Guide Bar & Chain: Place bar on studs, loop chain over sprocket and bar groove, tension chain correctly.
3. Fill Fluids: Add fuel mix (50:1 gasoline to STIHL HP Ultra oil) to fuel tank. Fill oil tank with STIHL chain oil.
4. Check Chain Brake: Pull brake lever back toward front handle; it should engage with a click. Push forward to disengage.
5. Start Engine: Place saw on firm ground, engage chain brake, set master control to choke, pull starter rope until engine fires, move control to fast idle, pull again to start.

WARNING! Never drop-start or start the saw above waist height. Always engage chain brake before starting.

Operation

Proper cutting techniques and operational procedures.

1. Starting a Cold Engine: Set master control to choke (full down). Pull starter rope 2-3 times until engine 'pops'. Move control to half-throttle position. Pull starter rope to start. Allow brief warm-up.
2. Starting a Warm Engine: Set master control to half-throttle position. Pull starter rope.
3. Stopping Engine: Push master control up to the stop position.
4. Basic Cutting: Use full throttle during cut. Let chain do the work; do not force. Be aware of pinch points, kickback zones, and falling material.
5. Chain Brake Use: Manually engage for any pause in cutting or when moving between cuts. Test automatic function periodically by rotating saw quickly (chain stopped).

CAUTION! Always plan your cut and escape path. Never cut with the tip of the bar to avoid kickback.

Maintenance Schedule

Routine service intervals to ensure optimal performance and safety.

Interval	Task
Before Each Use	Check chain tension, sharpness, and lubrication. Test chain brake function. Inspect for loose fasteners.
After Each Use	Clean air intake, cooling fins, and saw exterior. Wipe down guide bar.
Every 5 Hours	Clean spark arrestor screen in muffler. Check fuel filter.
Every 20 Hours	Clean or replace air filter. Check spark plug condition and gap (0.5 mm / 0.020").
Every 50 Hours	Clean carburetor air passage. Check anti-vibration elements. Check clutch and sprocket.
Every 100 Hours	Clean fuel tank filter. Check all fuel lines for cracks. Decarbonize cylinder exhaust port.
Annually	Replace fuel filter. Have professional check ignition timing and compression.

Fuel & Lubrication

Correct fuel mixture and lubrication requirements.

• Fuel: Use unleaded gasoline with a minimum octane rating of 89 (RON). Do not use fuel containing more than 10% ethanol (E10).
• Oil Mix: Use high-quality two-stroke engine oil meeting ISO-L-EGD and JASO FD standards. STIHL HP Ultra is recommended.
• Mix Ratio: 50:1 (2% oil). For 1 US gallon of gasoline, add 2.6 fl oz of oil.
• Mixing: Add oil to an approved fuel can, then add gasoline. Shake thoroughly before refueling.
• Chain Oil: Use STIHL chain oil or a biodegradable alternative with good adhesive properties in temperatures above 14°F (-10°C). In colder conditions, use STIHL Arctic oil.
• Storage: For storage over 30 days, drain fuel tank and run engine dry. Treat fuel with stabilizer if storing with fuel.

WARNING! Never use straight gasoline, automotive motor oil, or dirty/wrong lubricants. This will cause engine seizure.

Chain & Bar Maintenance

Care for the cutting chain and guide bar.

1. Chain Tensioning: Loosen bar nuts. Using scrench tool, turn tensioning screw clockwise until cutters just contact bar rail. Tighten bar nuts while lifting bar tip. Re-check tension.
2. Sharpening: Use correct round file size (typically 4.0 mm / 5/32" for 3/8" PMM chain). Maintain 30° filing angle. File all cutters to equal length. File depth gauges with a flat file and gauge.
3. Bar Care: Regularly clean bar groove and oil holes. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
4. Sprocket Inspection: Check drive sprocket for wear. Replace if teeth are hooked or worn thin.
5. Lubrication Check: Run saw at full throttle, pointing bar at a light-colored surface (like a stump). A fine line of oil should be visible.

Engine Tuning & Carburetor

Adjusting the carburetor for optimal performance. Note: Some models have fixed-jet carburetors.

Adjustable Carburetor (if equipped):

• L (Low Speed) Screw: Controls fuel mixture at idle and low RPM. Turn clockwise to lean, counter-clockwise to enrich.
• H (High Speed) Screw: Controls mixture at full throttle. Turn clockwise to lean (increases RPM), counter-clockwise to enrich (decreases RPM).
• LA (Idle Speed) Screw: Sets idle RPM. Turn clockwise to increase, counter-clockwise to decrease.

Tuning Procedure:

1. Start engine and warm up for several minutes.
2. Set idle speed so chain does not move but engine runs smoothly.
3. Accelerate to full throttle. Listen for a smooth, consistent "4-stroking" sound (a slight burble) that clears up when cutting. If it screams without burble, it's too lean. If it burbles heavily and lacks power, it's too rich.
4. Fine-tune L screw for best acceleration from idle.
5. Re-check idle speed after adjustments.

CAUTION! An overly lean H setting can cause engine overheating and seizure. Final tuning should be done under load (cutting).

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, bad fuel, clogged filter	Check spark plug, dry plug, use fresh fuel mix, clean air filter.
Engine starts then dies	Clogged fuel filter/tank vent, dirty carburetor	Replace fuel filter, clean tank vent, clean carburetor.
Engine lacks power	Dirty air filter, clogged spark arrestor, improper carb adjustment	Clean/replace air filter, clean spark arrestor, tune carburetor.
Chain does not turn	Chain brake engaged, clutch worn, sprocket damaged	Disengage chain brake, inspect clutch springs and drum, replace sprocket.
Chain turns at idle	Idle speed set too high	Adjust LA screw to lower idle RPM.
Excessive vibration	Loose components, unbalanced chain, worn AV mounts	Tighten all fasteners, sharpen chain evenly, replace anti-vibration elements.
Chain throws oil but doesn't lubricate bar	Clogged oil passage in bar or pump	Clean oil holes in bar, check oil pump output and filter screen.
Overheating	Dirty cooling fins, lean carb setting, dull chain	Clean cylinder fins, enrich H screw slightly, sharpen chain.

Parts List & Diagrams

Reference for ordering genuine STIHL replacement parts. Diagrams include: Cylinder/Piston Assembly, Carburetor/Fuel System, Ignition System, Clutch/Sprocket Assembly, Anti-Vibration System, and Guide Bar/Chain Components.

Common Replacement Part Numbers (Example):

• Air Filter: 0000 120 1605
• Spark Plug: BOSCH WSR6F or NGK BPMR7A (gap 0.5mm)
• Fuel Filter: 0000 350 3501
• Complete Carburetor Kit: 0000 120 0600
• Chain Brake Band: 1115 160 4501
• Clutch Drum & Sprocket: 1115 160 4003
• Guide Bar (16"): 3003 000 2016
• Chain (3/8" PMM, 16"): 63 PMM 68 Drive Links

Service Support: For technical assistance or to order parts, contact an authorized STIHL servicing dealer or visit www.stihlusa.com.