How To Change Chainsaw Chain Stihl Safely & Step-by-Step

Can I change a Stihl chainsaw chain myself? Yes, you absolutely can change a Stihl chainsaw chain yourself. It’s a straightforward maintenance task that, when done correctly, ensures your saw operates efficiently and safely. This guide will walk you through every step of the Stihl chainsaw chain replacement process, from gathering your tools to the final tension check. Performing a Stihl chainsaw bar and chain replacement or simply changing the chain is crucial for effective woodcutting.

Gathering Your Stihl Chainsaw Parts and Tools

Before you start, ensure you have all the necessary Stihl chainsaw parts and tools. This preparation makes the process smooth and safe.

New Chain for Stihl Chainsaw: Make sure the new chain matches your chainsaw model and bar specifications. Check the owner’s manual or the side of your current chain for the correct pitch, gauge, and drive link count.
Owner’s Manual: Your Stihl chainsaw’s manual is your best friend. It contains specific information about your model.
Scrench or Combination Tool: Most Stihl chainsaws come with a specialized tool, often called a scrench, which combines a spark plug wrench and a flathead screwdriver for adjusting the chain tension.
Gloves: Heavy-duty work gloves protect your hands from sharp chain teeth and prevent cuts.
Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.
Bar Groove Cleaner: A small tool to clean the bar groove where the chain runs.
Rag: For wiping down parts.
Chain Oil: You’ll need to lubricate the new chain.

Pre-Change Safety Checks

Safety is paramount when dealing with any power tool, especially a chainsaw. Perform these checks before you begin changing a Stihl chainsaw chain:

Disengage the Chain Brake: Ensure the chain brake is engaged. This prevents the chain from accidentally moving.
Turn Off the Engine: Make absolutely sure the chainsaw is turned off and the spark plug wire is disconnected. This is a critical step to prevent accidental starting.
Cool Down: Allow the chainsaw to cool down completely, especially the engine and the bar. A hot chain and bar can cause severe burns.

Step-by-Step Guide to Changing Your Stihl Chainsaw Chain

Follow these steps carefully for a successful Stihl chainsaw chain replacement.

Step 1: Accessing the Chain and Bar

Locate the Chain Cover: On most Stihl chainsaws, the chain and bar are covered by a chain brake housing or cover.
Remove the Cover Nuts: You’ll find nuts that secure this cover. Use your scrench to loosen and remove these nuts. Keep them in a safe place, as they are small and easy to lose.
Remove the Chain Cover: Gently lift off the chain cover. Be mindful of the chain brake mechanism, which might be attached to the cover.

Step 2: Loosening the Bar Nuts and Releasing Tension

Identify Bar Nuts: You’ll see nuts that hold the guide bar firmly in place. These are the bar nuts.
Loosen the Bar Nuts: Use your scrench to loosen these nuts. You don’t need to remove them completely, just loosen them enough to allow the bar to move. This action also releases some of the chain tension.

Step 3: Removing the Old Chain

Slide the Bar Forward: Gently push the guide bar forward towards the front of the chainsaw. This will create slack in the old chain.
Remove the Old Chain: With the bar pushed forward, you can now lift the old chain off the guide bar and the drive sprocket.

Step 4: Cleaning the Bar and Sprocket

This is a vital part of Stihl chainsaw maintenance. A clean workspace ensures the new chain runs smoothly.

Clean the Bar Groove: Use your bar groove cleaner or a small screwdriver to remove sawdust, wood chips, and old oil from the groove in the guide bar. A clogged groove can affect chain performance and bar life.
Inspect the Sprocket: Check the drive sprocket for wear or damage. If it looks worn, it might be time to replace it as well. This is a good time to do so if you have a new sprocket on hand.
Clean the Chain Cover: Wipe down the inside of the chain cover and the area around the clutch.

Step 5: Fitting the New Chain

Orient the New Chain: Examine your new chain. Most chains have cutters that are angled to face forward on the top of the bar. Ensure the cutters are facing the correct direction for cutting.
Place the Chain on the Bar: Carefully place the new chain into the groove of the guide bar. Ensure all the drive links are seated correctly in the bar groove.
Engage the Drive Sprocket: Guide the chain over the drive sprocket, making sure the drive links engage with the sprocket teeth.

Step 6: Positioning the Guide Bar

Adjust the Guide Bar: Move the guide bar back to its original position.
Engage Chain Tensioning Mechanism: Stihl chainsaws typically have a chain tensioning system. This can be either a screw located on the side of the chainsaw (accessible when the cover is off) or a knob on the front of the saw (on some newer models). Refer to your manual for the exact location and operation of your model’s tensioner.
Adjust Tension: Slowly turn the tensioning screw or knob. As you turn it, the guide bar will move forward, and the chain will become taut.

Step 7: How to Tension Chainsaw Chain Stihl Correctly

Proper chain tension is critical for both safety and performance. An incorrectly tensioned chain can cause premature wear on the bar, chain, and sprocket, or even derail from the bar.

Initial Tensioning: With the guide bar in place and the chain on the sprocket, start turning the tensioning screw.
Checking Tension: The chain should be snug against the bottom of the guide bar, but you should still be able to pull it around the bar by hand.
The “Pull Test”: Grab the chain in the middle of the bar’s underside (the part that contacts the wood). You should be able to pull it forward slightly.
Correct Tension: The chain should move freely by hand but have no noticeable sag. When you pull the chain, it should snap back into place without being excessively loose.
Tightening the Bar Nuts: Once you have the correct tension, tighten the bar nuts securely with your scrench.

Step 8: Final Tension Check After Tightening Bar Nuts

It’s important to re-check the chain tension after tightening the bar nuts, as they can sometimes slightly alter the tension.

Re-check Tension: Perform the “pull test” again. The chain should still move freely by hand, with no sag.
Make Adjustments: If the chain is too tight (it doesn’t move freely) or too loose (it sags), loosen the bar nuts slightly, adjust the tensioner, and retighten the bar nuts. Repeat this process until the tension is correct.

Step 9: Reattaching the Chain Cover

Position the Cover: Carefully place the chain cover back onto the chainsaw, ensuring it sits correctly over the bar and chain.
Reinstall Nuts: Screw the cover nuts back on and tighten them firmly with your scrench. Do not overtighten, as this can strip the threads.

Step 10: Final Safety Check and Testing

Reconnect Spark Plug Wire: Reconnect the spark plug wire securely.
Engage Chain Brake: Ensure the chain brake is engaged before starting the saw.
Start the Saw: Start the chainsaw as you normally would.
Test Run: Allow the saw to run for a few moments. Then, disengage the chain brake and briefly run the chain.
Observe Chain Behavior: The chain should move smoothly. Stop the saw and check the chain tension one last time. It might stretch slightly after the first run. Adjust if necessary.

Maintaining Your Stihl Chainsaw Bar and Chain

Proper maintenance extends the life of your Stihl chainsaw bar and chain and ensures optimal cutting performance.

Regular Cleaning: Clean the bar groove and oil holes after each use.
Chain Sharpening: A sharp chain cuts more efficiently and safely. Learn Stihl chainsaw chain sharpening techniques or have it professionally sharpened. Regular Stihl chainsaw chain sharpening is crucial.
Bar Lubrication: Always ensure the bar is properly lubricated with chain oil. Check that the oiler is working correctly by observing a thin stream of oil hitting the ground when the saw is running.
Bar Rotation: Rotate your guide bar every time you change the chain. This helps ensure even wear on both sides of the bar.
Chain Replacement: Replace chains that are significantly worn, stretched, or have damaged cutters.

Common Stihl Chainsaw Troubleshooting Issues Related to the Chain

Sometimes, after changing a chain, you might encounter issues. Here are a few common Stihl chainsaw troubleshooting tips:

Problem	Possible Cause	Solution
Chain too loose	Improper tensioning	Loosen bar nuts, retension chain, tighten bar nuts.
Chain too tight	Over-tensioning	Loosen bar nuts, release tension slightly, tighten bar nuts.
Chain derails from bar	Incorrect tension, worn bar groove, damaged chain, or bar mounts misaligned	Check tension, clean bar groove, inspect chain for damage, ensure bar is seated correctly.
Chain not cutting straight	Dull chain, incorrect chain type, or bent guide bar	Sharpen or replace chain, verify correct chain specifications, inspect guide bar for damage.
Chain not moving when throttle applied	Chain brake engaged, chain too tight, or drive sprocket issue	Disengage chain brake, check and adjust tension, inspect drive sprocket for wear or damage.
Chain not picking up oil	Blocked oiler holes, low oil level, or faulty oiler pump	Clean oiler holes in the bar, refill oil reservoir, check oiler system.

Frequently Asked Questions About Stihl Chainsaw Chain Replacement

Q1: How often should I replace my Stihl chainsaw chain?
A: You should replace your chain when it shows signs of significant wear, such as dulling quickly, stretching excessively, or having damaged cutters. Most chains can be sharpened several times before needing replacement. Always replace if the chain is visibly stretched or if the cutters are uneven.

Q2: What is pitch, gauge, and drive link count?
A: These are the key specifications for a new chain for Stihl chainsaw.
* Pitch: The distance between any three consecutive rivets on the chain, divided by two. It’s usually measured in inches (e.g., 3/8″, .325″).
* Gauge: The thickness of the drive links that fit into the bar groove. It’s usually measured in millimeters or inches (e.g., 1.3mm, .050″).
* Drive Link Count: The number of drive links on the chain. This must match the length of your guide bar.

Q3: Can I use a different brand of chain on my Stihl chainsaw?
A: While you can use chains from other reputable manufacturers, ensure they precisely match your Stihl chainsaw’s specifications for pitch, gauge, and drive link count. Using the wrong specifications can damage your saw. Stihl chains are designed to work optimally with their bars.

Q4: How tight should the chain be on my Stihl chainsaw?
A: The chain should be snug against the bottom of the bar but still be able to be pulled around the bar by hand. There should be no sag. You should be able to pull the chain by hand with your gloved fingers.

Q5: What are the signs of a worn guide bar?
A: Signs of a worn guide bar include a widened groove, burrs along the edges, or a “hooked” appearance to the rails. If the bar is significantly worn, it can damage the new chain and affect cutting performance. Always check your bar when changing the chain.

Changing your Stihl chainsaw chain is an essential maintenance task that ensures your equipment is ready for any job. By following these steps and prioritizing safety, you can confidently perform this task and keep your Stihl chainsaw running at its best. Remember, proper Stihl chainsaw maintenance like regular cleaning and sharpening, along with correctly changing a Stihl chainsaw chain, will prolong the life of your saw and its components.