Stihl 041 Chainsaw Manual

The Stihl 041 is a professional-grade gasoline-powered chainsaw known for its durability, power, and reliability in demanding cutting applications. This manual covers essential information for safe operation, maintenance, troubleshooting, and specifications to ensure optimal performance and longevity of your chainsaw.

1. Safety Information & Warnings 2. Features & Components 3. Assembly & Initial Setup 4. Technical Specifications 5. Controls & Operation 6. Fuel & Lubrication 7. Chain & Bar Maintenance 8. Engine Maintenance 9. Storage Guidelines 10. Warranty Information 11. Troubleshooting Guide

Safety Information & Warnings

Operating a chainsaw involves significant risk. Always read and understand all safety instructions before use.

Hazard	Precaution
Kickback	Always grip saw firmly with both hands; use reduced-kickback chain; do not saw with tip.
Hearing Damage	Wear approved hearing protection during operation.
Eye Injury	Always wear safety glasses or face shield.
Fire/Explosion	Refuel in well-ventilated area with engine off and cool. No smoking.
Vibration	Take regular breaks to reduce risk of Hand-Arm Vibration Syndrome (HAVS).
Falling Branches	Be aware of your surroundings, especially during felling operations.

Features & Components

Key components of the Stihl 041 chainsaw for identification and operation.

Engine: Two-stroke, single-cylinder gasoline engine.
Starter: Manual recoil starter with decompression valve.
Fuel Tank: Integrated tank with filler cap.
Oil Tank: For automatic chain lubrication.
Guide Bar: Various lengths available (typically 16" to 20").
Saw Chain: .404" or 3/8" pitch, depending on configuration.
Throttle Trigger & Lockout: For controlled acceleration and safety.
Chain Brake: Inertia-activated for kickback protection.
Muffler: Spark-arresting muffler for reduced emissions and noise.

Assembly & Initial Setup

Assembling your chainsaw from the box for first-time use.

Attach Guide Bar & Chain: Place bar on studs, loop chain over sprocket and bar, adjust tension.
Fill Fuel Tank: Use fresh, high-quality gasoline mixed with 2-stroke oil at 50:1 ratio (Stihl HP Ultra recommended).
Fill Chain Oil Tank: Use Stihl chain oil or a quality substitute for proper lubrication.
Check Chain Tension: Chain should be snug against bar but pull freely by hand.

WARNING! Never operate the saw without proper chain tension and lubrication. Ensure all fasteners are secure.

Technical Specifications

Engine Displacement: 61 cc (3.7 cu. in.)
Power Output: Approximately 4.0 HP
Fuel Capacity: 0.55 US pt (0.26 l)
Oil Tank Capacity: 0.42 US pt (0.20 l)
Weight (Powerhead): 12.8 lbs (5.8 kg) without bar and chain
Ignition System: Electronic, breakerless
Recommended Bar Lengths: 16" to 20"
Chain Pitch: .404" or 3/8"
Sound Pressure Level: ~112 dB(A)
Vibration Level (Front/Rear Handle): ~6.5/4.5 m/s²

Controls & Operation

Understanding the controls for safe and effective cutting.

Master Control Lever: Combines stop switch, choke, and run positions for starting.

Throttle Trigger: Controls engine speed. Throttle lockout must be depressed to engage.

Chain Brake/Front Hand Guard: Push forward to activate brake manually; inertia activates it during kickback.

Decompression Valve: Reduces compression for easier starting. Press before pulling starter.

Starting Procedure: 1. Engage chain brake. 2. Set Master Control to choke (cold start). 3. Press decompression valve. 4. Pull starter cord until engine 'pops'. 5. Move Master Control to run. 6. Pull starter cord to start. 7. Briefly blip throttle to disengage fast idle.

Fuel & Lubrication

Proper fuel mix and lubrication are critical for engine life.

Fuel Mix: Use 89 octane (or higher) unleaded gasoline mixed with a high-quality 2-stroke engine oil at a 50:1 ratio.
Chain Oil: Use proper chain oil. Check oil level before each use. Adjust oil flow rate via screw if needed.
Air Filter: Clean regularly (every 5-10 hours of use) with compressed air or soapy water. Replace if damaged.

CAUTION! Never use straight gasoline or automotive motor oil. Never use old fuel mix (over 30 days).

Chain & Bar Maintenance

Regular maintenance ensures cutting efficiency and safety.

Sharpening: Use correct round file size for your chain. Maintain correct filing angle (typically 30°). File all cutters evenly.
Tensioning: Chain should be tensioned when cold. Adjust via side tensioning screw. Proper tension: snug against bar but pull freely.
Bar Maintenance: Regularly clean bar groove. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
Sprocket: Inspect drive sprocket for wear. Replace if teeth are hooked or significantly worn.

Engine Maintenance

Scheduled maintenance tasks for reliable engine performance.

Component	Interval	Action
Spark Plug	Every 50 hours	Clean, check gap (0.020"), replace if electrodes are worn.
Fuel Filter	Every 100 hours	Replace in-tank fuel filter.
Muffler & Spark Arrestor Screen	Every 100 hours	Clean carbon deposits from muffler and screen.
Cylinder Fins	Every 10 hours	Clean cooling fins to prevent overheating.
Carburetor Adjustment	As needed	Adjust idle (L) and high-speed (H) screws for smooth operation. Consult dealer if unsure.

Storage Guidelines

Proper storage prevents fuel system issues and corrosion.

Long-Term Storage: Run engine dry of fuel or add fuel stabilizer. Empty chain oil tank.
Clean: Thoroughly clean saw of dirt, sap, and debris.
Chain: Remove chain, clean, and soak in oil. Store bar flat.
Location: Store in a dry, secure place, out of reach of children.

Tip: Before storing, perform all scheduled maintenance so saw is ready for next use.

Warranty Information

Stihl offers a limited warranty for the 041 chainsaw. Proof of purchase from an authorized Stihl dealer is required. Warranty covers defects in materials and workmanship under normal use. It does not cover damage from misuse, neglect, improper maintenance, or use of non-genuine Stihl parts. For warranty service, contact the authorized Stihl dealer where the product was purchased.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, bad fuel, clogged filter	Check spark plug; set Master Control to run; use fresh fuel mix; clean/replace fuel filter.
Engine starts then dies	Clogged air filter, carburetor adjustment, fuel vent blocked	Clean air filter; adjust carburetor (L screw); check tank vent.
Engine lacks power	Dirty air filter, clogged muffler, carburetor issue	Clean air filter and muffler spark arrestor; check carburetor settings.
Chain does not turn	Chain brake engaged, clutch worn, sprocket damaged	Disengage chain brake; inspect clutch and sprocket for wear.
Chain throws oil excessively	Oil flow rate too high	Adjust oil pump flow rate screw counter-clockwise.
Chain gets dull quickly	Cutting dirty wood, hitting ground, improper filing	Avoid cutting into dirt; sharpen correctly with proper file.

Service: For complex repairs, contact an authorized Stihl servicing dealer.

Support: Stihl Inc., 536 Viking Drive, Virginia Beach, VA 23452. Customer Service: 1-800-467-8445.