Replacing a STIHL Chainsaw Chain: Safety & Step-by-Step Guide

Before removing or fitting a chain, always ensure the saw **cannot** start unexpectedly. According to STIHL, for a cordless saw remove the battery and apply the chain brake; for an electric cord model unplug and apply the chain brake; for petrol models switch off the engine, set the combi-lever to “0” and apply the chain brake.

• Wear gloves made of robust material and eye protection.
• Work on a stable surface, cool engine, chain brake engaged.
• Ensure you have the correct replacement chain and bar combination for your machine.

The procedure for fitting the cutting attachment is similar for electric, cordless and petrol models – the key difference is the tensioning device type (quick nut, side tensioner or front tensioner).

• Release the chain brake. Remove the chain sprocket cover (wing-nut or bolts depending on model).
• Remove the old chain and guide bar. Inspect bar, sprocket and groove for wear or damage.
• Install the new chain ensuring the drive links locate into the sprocket, and the cutters’ arrows point in the correct direction of rotation.
• Replace the guide bar and ensure the pins line up; reinstall sprocket cover but do not fully tighten yet.

Installing the new chain

Ensure drive links engage the sprocket and cutters are oriented correctly.

Correct chain tension is essential for safe and efficient operation. After replacing the chain, adjust tension while bar tip is lifted slightly so the chain sags minimally; then tighten the cover fully.

• With tip lifted, adjustment screw or wheel is turned until slack is removed; drive links should just move freely.
• Tighten sprocket cover wing-nut or bolts securely.
• Check that chain oil reservoir is filled, oil holes and bar groove are cleared, and run saw at idle to verify smooth movement before cutting.

Once your chain is replaced and tensioned correctly, it’s a great time to perform maintenance checks. Wear protective gloves, clean the bar groove and oil channels, check sprocket wear, and monitor chain condition throughout use.

• Inspect the sprocket for wear marks (replace if wear > 0.5 mm).
• Clean the bar groove and oil holes; ensure lubrication flows freely.
• After initial use with new chain, re-check tension and bar alignment.

Post-Replacement Checks

Checking sprocket wear and lubrication ensures long chain life.

• Ensure the saw is powered off and brake applied before any work.
• Remove sprocket cover, old chain + bar, inspect parts.
• Install new chain correctly with correct orientation and drive links engaged.
• Tension the chain, fill oil, tighten cover and run idle test.
• Perform maintenance checks and keep a periodic schedule to ensure safe operation.

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