STIHL Pole Saw Repair Manual

The STIHL Pole Saw Repair Manual provides comprehensive guidance for the maintenance, troubleshooting, and repair of STIHL pole saw models. It covers safety procedures, component identification, common issues, disassembly/assembly steps, and specifications to ensure proper functioning and longevity of your equipment. Below are key sections for safety, features, maintenance, troubleshooting, and repair procedures.

1. Safety Precautions 2. Tool Overview & Components 3. Maintenance Schedule 4. Specifications 5. Common Issues & Diagnostics 6. Disassembly Instructions 7. Repair Procedures 8. Reassembly & Testing 9. Parts List & Ordering 10. Warranty Information 11. Troubleshooting Guide

Safety Precautions

Always prioritize safety when performing repairs. Key safety components: Chain brake, throttle lockout, rear hand guard, spark arrestor.

Safety Feature	Description
Chain Brake	Stops chain rotation in kickback situations
Throttle Lockout	Prevents accidental throttle engagement
Rear Hand Guard	Protects hands from debris and chain
Spark Arrestor	Prevents sparks from exiting muffler
Anti-Vibration System	Reduces operator fatigue
Chain Catcher	Catches broken chain
Right Hand Guard	Additional protection for right hand
Stop Switch	Immediately stops engine
Debris Shield	Shields operator from sawdust
Wear Protective Gear	Always use gloves, goggles, helmet

Tool Overview & Components

Identify all major components before repair.

Engine Assembly: Includes cylinder, piston, carburetor, spark plug.
Drive System: Clutch, sprocket, drive shaft, gearbox.
Cutting Attachment: Guide bar, saw chain, tensioning system.
Pole Assembly: Extension poles, coupling mechanism.
Control Handle: Throttle trigger, lockout, stop switch.

WARNING! Disconnect spark plug wire before any repair to prevent accidental starting.

Maintenance Schedule

Regular maintenance prevents major repairs.

Daily: Clean air filter, check chain tension, inspect guide bar.
Weekly: Clean spark arrestor, check fuel filter, lubricate drive shaft.
Monthly: Check clutch springs, inspect anti-vibration elements, verify throttle operation.
Annually: Replace fuel lines, check cylinder compression, inspect gearbox grease.

CAUTION! Use only STIHL-approved parts and lubricants.

Specifications

Engine Type: 2-stroke gasoline engine.
Displacement: Varies by model (typically 25-40cc).
Power Output: 1.5-2.5 kW.
Fuel/Oil Ratio: 50:1 (STIHL HP Ultra oil).
Guide Bar Length: 10-16 inches.
Chain Pitch: 1/4" or .325".
Maximum Reach: 10-15 feet with extensions.
Weight: 10-15 lbs (without pole extensions).
Sound Level: 105 dB(A) typical.
Vibration Level: <2.5 m/s² front/rear handle.

Common Issues & Diagnostics

Access troubleshooting via symptom analysis. Common problems: Engine won't start, loss of power, chain won't turn, excessive vibration.

Diagnostic Tools: Compression tester, spark tester, multimeter, tachometer.

Fuel System: Check fuel lines, filter, carburetor diaphragms. Ignition: Test spark plug, ignition coil, stop switch. Mechanical: Inspect clutch, sprocket, drive shaft, gearbox. Cutting Attachment: Check chain sharpness, bar groove, tensioner.

Disassembly Instructions

Follow proper sequence for disassembly.

Remove cutting attachment: Loosen nuts, remove bar and chain.
Disassemble pole: Uncouple extension sections.
Remove engine cover: Remove screws, lift cover carefully.
Access internal components: Carburetor, fuel system, ignition.

Tip: Take photos during disassembly for reference during reassembly.

Repair Procedures

Step-by-step repair instructions for common issues.

Carburetor Repair: Clean jets, replace diaphragms, adjust H/L screws.
Ignition System: Test coil resistance (3-6 kΩ), replace spark plug.
Clutch Replacement: Remove clutch drum, replace springs/shoes.
Chain Brake Repair: Replace band, check activation mechanism.
Fuel System: Replace lines, filter, tank vent.
Gearbox Service: Clean old grease, repack with STIHL grease.
Anti-Vibration: Replace rubber dampeners.
Throttle Linkage: Adjust cable, lubricate pivot points.

WARNING! Use proper torque values when tightening fasteners.

Reassembly & Testing

Reassemble in reverse order of disassembly. Test thoroughly before use.

Parts List & Ordering

Use genuine STIHL parts. Reference model number for correct parts.

CAUTION! Non-genuine parts may void warranty and cause safety issues.

Warranty Information

STIHL limited warranty covers defects in materials/workmanship. Commercial use may have different terms. Keep purchase receipt for warranty claims. For support, visit www.stihlusa.com or contact 1-800-467-8445.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel freshness, spark plug, compression (≥100 psi).
Engine starts then dies	Fuel delivery, carburetor	Clean fuel filter, check tank vent, rebuild carburetor.
Loss of power	Air filter, exhaust, carburetor	Clean/replace air filter, clean spark arrestor, adjust carburetor.
Chain won't turn	Clutch, sprocket, drive shaft	Inspect clutch springs, sprocket wear, drive shaft alignment.
Excessive vibration	Balance, anti-vibration, loose parts	Check anti-vibration elements, tighten all fasteners.
Chain won't stay tight	Tensioner, bar wear	Replace tensioner mechanism, inspect bar for wear.
Oil not reaching chain	Oil pump, passages, tank	Clean oil passages, check pump operation, verify oil tank vent.
Overheating	Air flow, fuel mixture, carbon	Clean cooling fins, check fuel ratio, decarbonize exhaust.

Reset: After repairs, reset carburetor to factory settings.

Service: 1-800-467-8445; www.stihlusa.com