How To Change Chain On Stihl Chainsaw: Easy Steps

Can you change a Stihl chainsaw chain yourself? Yes, absolutely! Changing a Stihl chainsaw chain is a straightforward maintenance task that most owners can perform with a few basic tools and this guide.

A sharp, properly tensioned chain is vital for your Stihl chainsaw’s performance and safety. A dull or loose chain makes cutting difficult, strains the engine, and can even be dangerous. Thankfully, Stihl chainsaw chain replacement is a manageable process. This guide will walk you through each step, ensuring you can confidently perform this essential Stihl chainsaw maintenance chain task.

Why Change Your Stihl Chainsaw Chain?

Chainsaws are workhorses, and their chains are the part that does the most direct work. Over time, the cutters on a chain wear down. This wear isn’t always obvious, but it significantly impacts how well your saw cuts. Here are common reasons for Stihl chainsaw chain replacement:

Dullness: Even with good care, chains get dull from cutting wood, especially dirt or grit-laden logs. A dull chain will “chew” rather than cut cleanly.
Damage: Hitting rocks, metal, or even hard knots can nick, bend, or break chain cutters. Damaged cutters are dangerous and inefficient.
Wear: Over extended use, the entire chain stretches and wears down. This includes the depth gauges and drive links.
Chain Type Change: You might want to switch to a different type of chain, such as a ripping chain for milling or a specialized low-kickback chain for safety.

Tools You’ll Need for Stihl Chainsaw Chain Replacement

Gathering the right tools beforehand makes the process much smoother. For installing new Stihl chainsaw chain, you’ll typically need:

Gloves: To protect your hands from sharp chain edges and bar oil.
Spark Plug Wrench/Scrench: Most Stihl chainsaws use a combined tool (often called a “scrench”) that fits the spark plug and bar nuts.
Bar Nut Wrench: If your scrench doesn’t have this function, you’ll need a wrench that fits the bar nuts.
Tensioning Tool/Screwdriver: Depending on your Stihl model, you might need a flathead screwdriver or a specific tensioning tool for the chain tension adjustment mechanism.
Wire Brush: Useful for cleaning the bar groove and around the drive sprocket.
Rag: For wiping down parts and cleaning up oil.
New Stihl Chainsaw Chain: Ensure it’s the correct pitch, gauge, and drive link count for your specific saw and Stihl chainsaw bar and chain.

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

Follow these instructions carefully to ensure a correct and safe Stihl chainsaw chain replacement.

Step 1: Ensure Safety First

Before you begin any work on your chainsaw, safety is paramount.

Turn off the chainsaw: Make sure the engine is completely off and cool.
Engage the chain brake: This prevents the chain from moving accidentally.
Work on a stable surface: A workbench or a clear, flat area is ideal.
Wear protective gear: Always wear gloves.

Step 2: Loosen the Bar Nuts

Locate the nuts that secure the guide bar to the chainsaw body. These are usually on the side of the clutch cover.

Use your scrench or appropriate wrench to loosen these nuts. You don’t need to remove them completely at this stage, just loosen them enough so the clutch cover can move.

Step 3: Access the Chain and Bar

Most Stihl chainsaws have a clutch cover that needs to be removed to get to the chain.

Remove the clutch cover: Once the bar nuts are loosened, you should be able to slide or unbolt the clutch cover. Some models have a single large nut that holds the cover and the bar nuts together. If so, you’ll need to loosen or remove that.
Identify the chain tensioning mechanism: As you remove the cover, you’ll see the chain, the guide bar, and the clutch sprocket. Note how the chain is tensioned. Most modern Stihls use a side-mounted tensioner knob or screw. Older models might have a screw at the front of the bar.

Step 4: Remove the Old Chain

With the clutch cover off, you can now remove the old chain.

Release tension: If your saw has a manual tensioner, you might need to loosen it further to give the chain some slack.
Slide the bar: Gently pull the guide bar forward, away from the engine. This will create enough slack to lift the old chain off the clutch sprocket and out of the groove in the guide bar.
Inspect the clutch sprocket: While the chain is off, take a moment to inspect the clutch sprocket for wear. If it looks significantly grooved or damaged, it might be time to replace it as well. This is a good time to check the Stihl chainsaw drive sprocket.

Step 5: Prepare the Guide Bar and New Chain

Before installing new Stihl chainsaw chain, it’s wise to do some prep work.

Clean the guide bar: Use your wire brush to clean out the groove of the guide bar. This groove is where the drive links of the chain sit and where the Stihl chainsaw chain lubrication oil flows. Remove any sawdust, oil, or debris. Ensure the oil holes are clear.
Lubricate the new chain: Apply a bit of bar oil to the new chain, especially along the links and cutters. This helps with initial lubrication and reduces wear.
Check the new chain: Ensure you have the correct chain. Verify the pitch, gauge, and number of drive links match your saw’s specifications. This is crucial for proper fit and performance.

Step 6: Install the New Stihl Chainsaw Chain

Now it’s time for fitting Stihl chainsaw chain.

Position the guide bar: Slide the guide bar back into position, ensuring the oiler hole in the bar aligns with the oiler port on the saw body.
Place the chain on the sprocket: Loop the new chain around the clutch sprocket. Ensure the chain is oriented correctly. The cutters on top of the chain should be facing forward, away from you, to cut properly.
Guide the chain into the bar groove: Carefully guide the drive links of the chain into the groove of the guide bar, starting from the sprocket and working your way around to the tip of the bar.
Ensure even seating: Make sure the chain sits evenly in the bar groove all the way around.

Step 7: Tension the Chain

Proper Stihl chainsaw chain tension is critical for safe operation and chain/bar longevity.

Initial Tensioning:
- Side Tensioner Models: On most modern Stihl saws, there’s a tensioning screw or knob on the side of the saw, near the guide bar. Use a screwdriver or the tensioning knob to turn the screw clockwise. This will pull the guide bar forward, tightening the chain.
- Front Tensioner Models: If your saw has a tensioning screw at the front of the guide bar, you’ll use a flathead screwdriver to turn it clockwise.
The “Sag” Test:
- You want the chain to be snug enough that it doesn’t easily pull off the bar, but loose enough to move freely by hand.
- Pull the chain around the bar. It should move smoothly without binding.
- Gently pull down on the chain, about halfway between the bar and the clutch sprocket. The chain should just touch the bottom of the guide bar but not sag away from it. There should be no slack visible. A slight upward curve at the bottom of the bar is normal.
- Important: Do not overtighten the chain. This can cause excessive wear on the chain, bar, sprocket, and engine.

Step 8: Reattach the Clutch Cover and Bar Nuts

Once the chain is tensioned correctly, you can reassemble.

Replace the clutch cover: Slide the clutch cover back into place, ensuring it fits correctly over the guide bar and around the clutch sprocket.
Tighten the bar nuts: Hand-tighten the bar nuts first. Then, use your scrench or wrench to snug them up.
Final Tension Check: With the clutch cover and bar nuts snug, recheck the chain tension. You may need to make minor adjustments after the chain has settled slightly.
Tighten bar nuts fully: Tighten the bar nuts securely. Do not overtighten, but ensure they are firm.

Step 9: Final Check and Adjustments

Before you start cutting, perform these final checks.

Spin the chain by hand: With the chain brake disengaged, try to spin the chain by hand. It should move freely and smoothly. If it’s stiff or binds, you may need to slightly loosen the tension.
Check bar nut tightness again: Give the bar nuts one last check to ensure they are secure.
Test cut: Make a short test cut on a piece of scrap wood. Listen to the saw and observe how the chain performs.

How to Adjust Stihl Chainsaw Chain Tension

Chain tension can loosen during use, especially with a new chain as it stretches. Regular checks are essential for optimal performance and safety. This process is part of your ongoing Stihl chainsaw maintenance chain.

Safety First: Ensure the chainsaw is off, the chain brake is engaged, and the saw has cooled down.
Loosen Bar Nuts: Loosen the bar nuts slightly, just enough to allow the guide bar to move.
Adjust Tension:
- Side Tensioner: Turn the tensioning knob or screw clockwise to tighten the chain.
- Front Tensioner: Use a screwdriver to turn the tensioning screw clockwise.
Perform the Sag Test: As described in Step 7, pull the chain around the bar. It should move freely. Gently pull down on the chain about midway between the bar and sprocket. It should touch the bottom of the guide bar but not sag.
Tighten Bar Nuts: Once the tension is correct, hand-tighten the bar nuts, then secure them with your wrench.
Final Check: Spin the chain by hand to ensure it moves freely.

What is the correct Stihl chainsaw chain tension? The chain should be snug enough that it doesn’t sag away from the bottom of the guide bar when gently pulled down, but loose enough to be spun freely by hand.

Common Issues and How to Solve Them

Issue	Possible Cause	Solution
Chain too loose	Improper initial tensioning, chain stretch	Loosen bar nuts, increase tension, re-tighten bar nuts. Check again after a few minutes of use.
Chain too tight	Overtightened tensioner	Loosen bar nuts, slightly decrease tension, re-tighten bar nuts. Ensure chain spins freely.
Chain binding or stiff	Overtightened tension, debris in bar groove	Loosen tension slightly. Clean bar groove with a wire brush and check for debris. Ensure the chain is correctly seated in the bar groove.
Chain falling off the bar	Loose bar nuts, insufficient tension	Tighten bar nuts securely. Increase chain tension to the correct level.
Saw not cutting effectively	Dull chain, incorrect chain pitch/gauge, incorrect tension	Sharpen or replace the chain. Ensure you are using the correct Stihl chainsaw bar and chain specifications. Adjust tension as needed.

Changing Your Stihl Chainsaw Blade (Guide Bar)

While you’re changing the chain, it’s a good opportunity to inspect and potentially change the guide bar. The guide bar, often referred to colloquially as the “Stihl chainsaw blade“, also wears down over time.

Signs of a Worn Guide Bar:

Grooving: The groove where the chain runs can become worn down, especially on the sides.
“Hooking”: The tip of the bar can bend, causing the chain to run at an angle.
Worn Sprocket Nose: If your bar has a sprocket nose, check for wear and ensure it spins freely. A stiff or worn nose will increase friction and wear.

To change the guide bar:

Follow steps 1-4 above to remove the old chain and clutch cover.
Loosen and remove the bar nuts completely.
Lift the guide bar off the mounting studs.
Inspect the new chain and ensure it’s compatible with the guide bar.
Place the new guide bar onto the mounting studs, ensuring the oiler hole aligns with the oil port.
Proceed with installing new Stihl chainsaw chain as described above, then reattach the clutch cover and bar nuts.

Stihl Chainsaw Chain Lubrication

Proper Stihl chainsaw chain lubrication is crucial. The oil lubricates the chain, the guide bar groove, and the sprocket, reducing friction, heat, and wear.

Always Use Bar Oil: Do not use regular motor oil or other lubricants. Stihl bar oil is specifically formulated for this purpose.
Check the Oil Tank: Ensure the oil reservoir is full before each use.
Verify Oil Flow: During operation, you should see a fine mist of oil being thrown off the chain. If you don’t, check the oil tank, the oiler holes in the bar, and the oiler mechanism.

Frequently Asked Questions (FAQ)

Q: How often should I change my Stihl chainsaw chain?
A: This depends heavily on how much you use the saw and what you’re cutting. A good rule of thumb is to sharpen your chain regularly (every 5-10 minutes of actual cutting time). You’ll need to replace the chain when it can no longer be sharpened effectively, or if it becomes damaged. You might notice a significant drop in cutting performance, or the chain starts to “burn” the wood rather than cutting it.

Q: Can I use a different brand of chain on my Stihl chainsaw?
A: Yes, you can use chains from reputable aftermarket manufacturers, but it’s crucial to ensure the new chain has the exact same pitch, gauge, and number of drive links as your original Stihl chain. Using the wrong specifications can damage your saw.

Q: What is “chain stretch”?
A: Chain stretch isn’t the metal physically stretching. Instead, the rivets and joints between the chain links wear down over time, creating more slack between the links. This causes the chain to become loose and less effective. Regular adjust Stihl chainsaw chain tensioning is necessary to compensate for this wear.

Q: What does “pitch” and “gauge” mean for a chainsaw chain?
A:
* Pitch: This refers to the size of the chain, specifically the distance between rivets. It’s usually measured from the center of one rivet to the center of the next rivet, divided by two. Common pitches are 3/8” and .325”.
* Gauge: This refers to the thickness of the drive links, which sit in the guide bar groove. Common gauges are .050” and .063”.
You must match these specifications to your guide bar and saw.

Q: How do I know when to replace my Stihl chainsaw bar and chain?
A: Besides physical damage, look for significant grooving in the bar groove, a worn sprocket nose (if applicable), and chains that are difficult to keep tensioned correctly or don’t cut efficiently even after sharpening.

Changing your Stihl chainsaw chain is a fundamental skill that empowers you to keep your saw running efficiently and safely. By following these steps, you can confidently perform this essential piece of Stihl chainsaw maintenance chain, ensuring your Stihl chainsaw remains a reliable tool for all your cutting needs.