STIHL 011 Chainsaw Repair Manual

The STIHL 011 is a lightweight, professional-grade chainsaw known for its reliability and power-to-weight ratio. This repair manual covers essential maintenance, troubleshooting, and repair procedures for the STIHL 011 chainsaw, including engine disassembly, fuel system servicing, ignition system diagnostics, chain and bar maintenance, and safety precautions. Below are key sections for specifications, safety, maintenance schedules, troubleshooting, and step-by-step repair guides.

Specifications & Technical Data

Key technical specifications for the STIHL 011 chainsaw engine, dimensions, and performance characteristics.

Safety Precautions

Essential safety procedures to follow before performing any maintenance or repair work on the chainsaw.

1. Disconnect the spark plug wire to prevent accidental starting.
2. Allow the engine to cool completely before working on any components.
3. Work in a well-ventilated area away from open flames or sparks.
4. Wear appropriate personal protective equipment (PPE): safety glasses, gloves, and sturdy footwear.
5. Use only STIHL-approved replacement parts and tools.

WARNING! Fuel and oil are flammable. Handle with care and store in approved containers. Never operate a chainsaw that is damaged or improperly assembled.

Maintenance Schedule

Recommended maintenance intervals to ensure optimal performance and longevity of your STIHL 011 chainsaw.

1. Daily/Before Use: Check chain tension, sharpness, and lubrication. Inspect for loose fasteners and damage.
2. Every 10 Hours: Clean air filter, check spark plug condition, inspect fuel filter.
3. Every 20 Hours: Clean cooling fins, check clutch drum and sprocket for wear.
4. Every 50 Hours: Clean carburetor (external), check fuel lines and impulse line for cracks.
5. Every 100 Hours: Decarbonize exhaust port and muffler, check piston and cylinder for scoring.
6. Annually/Off-Season: Drain fuel system, perform complete inspection, replace worn components.

CAUTION! Adhering to the maintenance schedule is critical for safe operation and to prevent premature wear or failure.

Tools & Equipment Required

• Basic Hand Tools: Screwdrivers (flathead, Phillips), combination wrenches (8mm-13mm), Torx drivers (T27).
• Specialty STIHL Tools: Piston stop tool, flywheel puller, clutch removal tool, compression gauge.
• Cleaning Supplies: Carburetor cleaner, parts cleaning solvent, compressed air, shop rags.
• Measuring Tools: Feeler gauges (for spark plug gap), multimeter (for ignition testing).
• Safety Gear: Safety glasses, nitrile gloves, hearing protection.
• Lubricants & Fluids: STIHL HP Ultra 2-stroke oil, bar and chain oil, high-temperature grease.

Engine System Repair

Procedures for disassembling and servicing the engine cylinder, piston, crankshaft, and bearings.

Disassembly Steps: Remove muffler, cylinder cover, and carburetor. Use piston stop to hold crankshaft, then remove flywheel and clutch. Separate crankcase halves after removing all fasteners.

Inspection: Check cylinder walls for scoring or glaze. Measure piston skirt clearance with feeler gauge. Inspect connecting rod for play and crankshaft bearings for smooth rotation. Replace any components showing excessive wear or damage.

Reassembly: Apply sealant to crankcase mating surfaces. Install new crankcase seals. Torque fasteners to specification in a crisscross pattern. Ensure piston ring gaps are properly aligned.

Fuel System Service

Servicing the carburetor, fuel lines, fuel filter, and tank to ensure proper fuel delivery and engine performance.

1. Drain fuel tank completely.
2. Remove carburetor cover and air filter housing.
3. Disconnect fuel lines and impulse line from carburetor.
4. Remove carburetor mounting nuts and carefully detach carburetor.
5. Disassemble carburetor (noting diaphragm and gasket orientation), clean all jets and passages with solvent and compressed air.
6. Inspect fuel lines and impulse line for brittleness or cracks; replace if necessary.
7. Replace in-tank fuel filter. Reassemble in reverse order, ensuring all connections are tight.

Tip: Use a carburetor rebuild kit for best results, which includes new diaphragms, gaskets, and needle valve.

Ignition System Diagnostics

Testing and replacing the ignition coil, spark plug, and stop switch to resolve starting or running issues.

1. Spark Test: Remove spark plug, reconnect wire, ground plug base against cylinder. Pull starter rope – look for strong blue spark.
2. No Spark: Check spark plug gap (0.5 mm / 0.020 in). Replace plug. If still no spark, test ignition coil with multimeter (primary resistance: ~0.5-2.0 Ω, secondary: ~5k-15k Ω).
3. Coil Replacement: Remove flywheel (using puller). Unfastignition coil mounting screws. Install new coil, setting air gap with a business card (0.2-0.4 mm) between coil legs and flywheel magnets.
4. Stop Switch Test: Disconnect wire from coil. If spark returns, stop switch is faulty.

WARNING! Always disconnect spark plug wire before testing ignition components to prevent accidental starting.

Chain & Bar Maintenance

Proper care, sharpening, and replacement of the guide bar and saw chain.

1. Chain Tensioning: Loosen bar nuts. Adjust tensioning screw until chain fits snugly against bar but can be pulled around by hand. Retighten bar nuts.
2. Sharpening: Use a round file matching chain pitch (e.g., 4.0 mm for 3/8" PMM). Maintain original filing angle (typically 30°). File all cutters to equal length.
3. Bar Maintenance: Clean bar groove regularly. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
4. Lubrication: Ensure oiler port is clear. Always use proper bar and chain oil. Check oil flow by pointing bar tip at a light surface and running at high speed – a line of oil should appear.

CAUTION! A dull or loose chain increases kickback risk and causes premature wear. Always stop the engine before adjusting the chain.

Clutch & Sprocket Service

Inspecting, servicing, and replacing the centrifugal clutch and drive sprocket.

Note: A worn sprocket will accelerate chain wear and reduce cutting efficiency.

Troubleshooting Guide

Reset: For electronic issues, disconnect spark plug wire for 1 minute to reset ignition module.

Service: For genuine STIHL parts and technical support, contact your local authorized STIHL dealer or visit www.stihlusa.com.