STIHL Mini Boss Chainsaw Manual

The STIHL Mini Boss is a lightweight, professional-grade chainsaw designed for demanding cutting tasks. It features a powerful engine, advanced anti-vibration system, quick-stop chain brake, and STIHL's Ematic lubrication system for reduced oil consumption. Below are key sections for safety, features, operation, maintenance, troubleshooting, and specifications.

1. Features at a Glance 2. Safety Information 3. Assembly & Preparation 4. Specifications 5. Controls and Components 6. Starting & Stopping Procedure 7. Operation & Cutting Techniques 8. Maintenance Schedule 9. Chain Sharpening & Tensioning 10. Storage Guidelines 11. Troubleshooting

Features at a Glance

Key components: High-performance engine, Quickstop chain brake, STIHL Ematic chain lubrication, Anti-vibration system, Side-access chain tensioner, Decompression valve.

Feature	Description
Engine Type	2-stroke, single-cylinder gasoline engine
Displacement	XX.X cc (specific to model variant)
Guide Bar Length	Typically 14" to 16" options
Chain Brake	Quickstop inertia-activated safety feature
Anti-Vibration System	Reduces operator fatigue during extended use
Lubrication System	STIHL Ematic for efficient oil delivery
Fuel Tank Capacity	Approx. XX fl oz
Oil Tank Capacity	Approx. XX fl oz
Ignition System	Electronic, capacitor discharge
Weight (powerhead only)	Approx. X.X lbs

Safety Information

Read and understand all instructions before operation. Always wear proper PPE.

Personal Protective Equipment (PPE): Wear safety glasses, hearing protection, gloves, chainsaw chaps/pants, and sturdy boots.
Work Area Safety: Clear area of obstacles, ensure secure footing, keep bystanders at a safe distance.
Chain Brake Check: Verify proper function before each use by engaging brake with front hand guard.
Fuel Safety: Refuel in well-ventilated area, with engine off and cool. Use proper fuel/oil mix.

WARNING! Kickback can occur without warning. Always hold saw firmly with both hands, maintain proper grip, and do not cut with the tip of the bar.

Assembly & Preparation

Unpack and inspect contents. Assemble guide bar and chain.

Attach Guide Bar & Chain: Place chain on bar, align with sprocket, fit bar onto studs, tighten nuts finger-tight.
Tension Chain: Use side-access tensioner to achieve proper tension (chain should snap back when pulled from bar).
Fill Tanks: Add proper fuel/oil mixture (50:1 STIHL HP Ultra or equivalent) to fuel tank. Fill bar & chain oil tank with STIHL chain oil or equivalent.
Final Check: Ensure all fasteners are secure, chain brake disengaged, and chain moves freely.

CAUTION! Use only STIHL-approved guide bars, chains, and lubricants. Incorrect assembly can lead to serious injury.

Specifications

Model: STIHL Mini Boss (specific model number).
Engine Power: XX kW / XX hp.
Maximum Power Speed: X,XXX rpm.
Idle Speed: X,XXX rpm.
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra 2-stroke oil).
Sound Power Level: XX dB(A).
Vibration Levels (Front/Rear Handle): X.X / X.X m/s².
Chain Pitch/Gauge: X/X" / .XXX".
Recommended Bar Lengths: 14", 16".

Controls and Components

Main Controls: Master Control Lever (combines stop switch, choke, and fast idle), Throttle Trigger, Throttle Trigger Lockout, Chain Brake Lever/Hand Guard, Decompression Valve.

Components: Front Handle, Rear Handle, Fuel Tank Cap, Oil Tank Cap, Spark Plug, Muffler, Chain Catcher, Bumper Spike.

Master Control Positions: STOP (0), RUN (I), START/CHOKE (II). Chain Brake: Push forward to engage (brake on), pull back to disengage (brake off).

Starting & Stopping Procedure

Cold Start:

Place saw on firm, level ground. Engage chain brake.
Press decompression valve (if equipped).
Set Master Control to START/CHOKE (II).
Pump primer bulb (if equipped) until fuel is visible.
Hold saw firmly, pull starter rope sharply until engine fires once.
Move Master Control to RUN (I).
Pull starter rope again until engine starts.
Briefly blip throttle to disengage fast idle. Disengage chain brake.

Warm Start: Master Control to RUN (I). Pull starter rope.

Stopping: Release throttle, let engine idle. Move Master Control to STOP (0).

Operation & Cutting Techniques

Always use proper stance and grip. Let the saw do the work.

Felling: Plan escape path. Make notch cut (1/3 diameter), then felling cut. Use wedges if needed.
Limbing: Work from trunk outward. Support limb if possible. Beware of springback.
Bucking: Support log off ground. Cut from top side. For pinched bar, stop and use wedge.
Kickback Prevention: Maintain firm grip, do not cut with upper quadrant of bar tip, keep chain sharp and properly tensioned.

WARNING! Never operate saw above shoulder height or with one hand. Be aware of reactive forces.

Maintenance Schedule

Regular maintenance ensures performance and longevity.

Interval	Task
Daily/Before Use	Check chain tension, sharpness, and lubrication. Check all fasteners. Clean air intake.
Every 5 Hours	Clean spark arrestor screen (if equipped). Check fuel filter.
Every 20 Hours	Clean/replace air filter. Check spark plug.
Every 50 Hours	Clean cooling fins. Check anti-vibration elements.
Annually/As Needed	Replace fuel filter, spark plug. Clean carburetor (by qualified technician).

Chain Sharpening & Tensioning

A sharp, properly tensioned chain is essential for safety and performance.

Sharpening: Use correct round file size. Maintain specified filing angle (typically 30°). File all cutters to equal length. File depth gauges with flat file and gauge.
Tensioning: Loosen bar nuts. Turn tensioning screw clockwise until chain fits snugly against bar (lift from center of bar, links should pull out about halfway). Retighten bar nuts. Re-check tension after brief run-in.

CAUTION! Always wear gloves when handling chain. Chain is extremely sharp.

Storage Guidelines

For storage longer than 30 days, prepare saw to prevent fuel system damage.

Drain fuel tank and run engine until it stops to clear carburetor.
Remove chain, clean, and soak in oil. Clean entire saw.
Store in a dry, secure place, out of reach of children.

CAUTION! Never store saw with fuel in tank for extended periods. Use fuel stabilizer if short-term storage is unavoidable.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, stale fuel, clogged filter	Check spark plug, use correct starting procedure, use fresh fuel mix, clean/replace air filter.
Engine runs poorly/dies	Clogged fuel filter, dirty air filter, carb adjustment	Replace fuel filter, clean air filter, have carb serviced by dealer.
Chain does not turn	Chain brake engaged, clutch/sprocket worn, chain jammed	Disengage brake, inspect clutch drum and sprocket, clear obstruction.
Excessive chain wear/oil consumption	Incorrect tension, dull chain, wrong oil, clogged oil passages	Correct tension, sharpen chain, use proper bar & chain oil, clean oil ports.
Excessive vibration	Loose components, worn anti-vibration mounts, unbalanced chain	Tighten all fasteners, inspect/replace mounts, sharpen chain evenly.

Service: For repairs beyond basic maintenance, contact an authorized STIHL servicing dealer.

Support: Visit www.stihlusa.com or contact STIHL customer service.