stihl 041 av manual pdf

The STIHL 041 AV is a professional-grade gasoline-powered chainsaw featuring Anti-Vibration (AV) technology, a robust engine, and durable construction for demanding forestry and cutting tasks. This manual covers safety instructions, technical specifications, assembly, operation, maintenance, troubleshooting, and parts identification for the STIHL 041 AV chainsaw. Ensure you read and understand all sections before use.

1. Safety Instructions & Warnings 2. Features & Components 3. Technical Specifications 4. Assembly & Initial Setup 5. Fuel & Lubrication 6. Starting & Operating Procedures 7. Maintenance Schedule 8. Chain & Bar Care 9. Troubleshooting Guide 10. Parts Diagram & List 11. Warranty & Support

Safety Instructions & Warnings

Critical safety information to prevent injury or damage. Always wear appropriate PPE: helmet, eye protection, hearing protection, gloves, chainsaw chaps, and sturdy boots.

Hazard	Precaution
Kickback	Hold saw firmly with both hands; keep chain sharp; avoid contact with tip of bar.
Fuel Handling	Refuel in well-ventilated area, engine off and cool. Use approved fuel/oil mix.
Electrical Hazards	Keep away from power lines; do not operate in wet conditions.
Exhaust Fumes	Operate only in well-ventilated areas to avoid carbon monoxide poisoning.
Chain Brake	Test chain brake functionality before each use.
Work Area Safety	Clear area of obstacles, ensure secure footing, and keep bystanders away.

Features & Components

Key components of the STIHL 041 AV chainsaw.

Engine: Two-stroke, air-cooled gasoline engine.
Anti-Vibration System (AV): Reduces operator fatigue through dampened handles.
Ignition System: Electronic ignition (CDI) for reliable starting.
Chain Brake: Inertia-activated front hand guard for kickback protection.
Fuel & Oil Caps: Clearly marked for fuel mix and chain oil.
Bar & Chain: Various bar lengths available; uses STIHL Picco or Rollomatic chains.
Controls: Throttle trigger, throttle trigger lockout, stop switch, choke control.

WARNING! Never operate a chainsaw without proper training and safety equipment.

Technical Specifications

Engine Displacement: 61.5 cc (3.75 cu. in.)
Power Output: Approx. 3.5 kW (4.7 hp)
Fuel Capacity: 0.55 L (18.6 fl. oz.)
Oil Tank Capacity: 0.26 L (8.8 fl. oz.)
Recommended Bar Lengths: 40 cm (16") to 50 cm (20")
Chain Pitch: 3/8" or .325"
Weight (without cutting equipment): Approx. 6.2 kg (13.7 lbs)
Sound Pressure Level: Approx. 112 dB(A)
Vibration Level (Front/Rear Handle): Complies with relevant standards due to AV system.
Fuel/Oil Mix Ratio: 50:1 (STIHL HP Ultra oil recommended)

Assembly & Initial Setup

Assembling your STIHL 041 AV from the box.

Attach Guide Bar & Chain: Place bar on studs, loop chain onto sprocket and bar groove, tension correctly.
Fill Fluids: Add correct fuel/oil mix to fuel tank. Fill chain oil tank with STIHL chain oil.
Check Controls: Ensure throttle trigger, lockout, and stop switch move freely.
Inspect Chain Brake: Pull front hand guard forward; it should snap back and engage brake band.
Final Inspection: Check all nuts and bolts for tightness. Ensure chain is sharp and properly tensioned.

CAUTION! Always perform assembly on a clean, stable surface with the engine off.

Fuel & Lubrication

Proper fuel and lubrication are critical for performance and engine life.

Fuel Mix: Use unleaded gasoline with a minimum octane rating of 89 (RON). Mix with STIHL HP Ultra 2-stroke oil at a 50:1 ratio. Shake container thoroughly before refueling.

Chain Lubrication: Use STIHL chain oil or a high-quality biodegradable chain oil. Check oil flow before cutting by holding saw over light-colored surface and running at full throttle; a line of oil should appear.

WARNING! Never use straight gasoline, automotive motor oil, or dirty/oil mix. Store fuel in approved containers away from sparks or flame.

Starting & Operating Procedures

Correct starting sequence and operation techniques.

Cold Start: Place saw on firm ground. Engage chain brake. Set master control lever to choke (full down). Press decompression valve (if equipped). Pull starter rope sharply until engine fires. Move master control to half-throttle position. Pull starter rope again to start. Let engine warm up at idle.
Warm Start: Master control lever to half-throttle position. Pull starter rope.
Operation: Disengage chain brake. Use a firm two-handed grip. Let the chain do the cutting; avoid forcing the saw. Maintain a steady engine speed in the cut.
Stopping: Release throttle trigger. Allow engine to idle. Press stop switch to "0".

Tip: Practice starting and handling with the chain brake engaged and no load.

Maintenance Schedule

Regular maintenance ensures safety and longevity.

Interval	Task
Before each use	Check chain tension, sharpness, and lubrication. Inspect for loose fasteners. Test chain brake.
After each use	Clean air intake, cooling fins, and saw body. Wipe down guide bar.
Every 10 hours	Clean spark plug, check electrode gap (0.5 mm / 0.020"). Clean or replace air filter.
Every 20 hours	Check fuel filter and replace if clogged. Inspect spark arrestor screen (if equipped).
Every 50 hours	Replace spark plug. Clean cylinder fins thoroughly. Check clutch drum and sprocket for wear.
Annually or as needed	Have carburetor adjustment and compression checked by a STIHL servicing dealer.

Chain & Bar Care

Proper care of cutting equipment is essential for performance and safety.

Sharpening: Use a round file and file guide matching chain pitch. Maintain correct filing angle (typically 30°). File all cutters to equal length.
Tensioning: Chain should be snug against bar but pull freely by hand. Re-tension when chain feels loose (check frequently when new).
Bar Maintenance: Regularly clean bar groove and oil holes. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
Sprocket Inspection: Replace drive sprocket if worn or damaged to prevent rapid chain wear.

WARNING! Always wear heavy gloves when handling the chain. A dull chain increases kickback risk.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, old fuel, clogged filter	Check spark plug; use fresh fuel mix; clean air filter; avoid over-choking.
Engine starts but dies	Clogged fuel filter, dirty carburetor, faulty ignition	Replace fuel filter; clean carburetor; check for air leaks.
Loss of power	Clogged air filter, spark arrestor, poor fuel, exhaust port carbon	Clean/replace air filter; clean spark arrestor screen; use fresh fuel.
Chain does not turn	Chain brake engaged, clutch worn, sprocket damaged	Disengage chain brake; inspect clutch springs and drum; replace worn parts.
Excessive vibration	Loose components, unbalanced chain, AV mounts worn	Tighten all nuts/bolts; sharpen chain evenly; inspect AV buffers.
Chain throws oil but doesn't lubricate	Oil passage blocked, wrong oil viscosity	Clean oil holes in bar and saw; use recommended chain oil.

Reset: For persistent issues, consult an authorized STIHL dealer.

Parts Diagram & List

Reference diagram for major components (diagram would be inserted here in actual manual). Common replacement parts include:

Spark Plug: STIHL 0000 400 1300 (Bosch WSR6F)
Air Filter: STIHL 0000 120 1605
Fuel Filter: STIHL 0000 350 3501
Chain: STIHL 63PM (for 16" bar, 3/8" pitch, .063 gauge)
Guide Bar: STIHL 3005 000 4016 (Rollomatic 16")
Clutch Drum/Sprocket: STIHL 1115 640 2003
AV Buffer Set: STIHL 1115 790 3400

Note: Always use genuine STIHL parts for optimal performance and safety.

Warranty & Support

STIHL 041 AV is backed by a limited warranty. Refer to your original purchase documentation for specific terms and duration.

For Technical Support & Service:
Contact an authorized STIHL servicing dealer. Use the dealer locator at www.stihlusa.com.
Customer Service: 1-800-467-8445 (USA)
Always provide model number (041 AV) and serial number when requesting service or parts.

Safety & Training: STIHL offers chainsaw safety training. Contact your dealer or visit the STIHL website for information.