How to Reassemble a Stihl Pole Saw Chain: Complete Guide

Ever found yourself in a sticky situation with your Stihl pole saw chain slipping off at the worst possible moment? Frustrating, right? Don’t worry, you’re not alone in this. Imagine effortlessly getting that chain back on in no time, saving you from further headaches during your yard work. In this article, you’ll discover simple steps to tackle this common issue and get your Stihl pole saw back in action swiftly. Let’s dive in and make your next chainsaw adventure a smooth and hassle-free one.

Assessing the Situation

When the chain on your Stihl pole saw slips off, don’t fret – it’s a common issue that can be resolved with a bit of know-how. Here’s how to assess the situation:

  • Check for any visible damage or wear on the chain. If you notice any, it may be time to replace it.
  • Inspect the guide bar to ensure it’s straight and in good condition. Any bends or damage could be causing the chain to slip.
  • Examine the chain tension. It should be snug against the guide bar but still able to move freely.
  • Verify that the chain is correctly installed. Sometimes, it can slip off if it’s not aligned properly.
  • Look for any debris or obstructions that may be affecting the chain’s movement. Clearing out any debris can sometimes solve the issue.
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By assessing these key factors, you can pinpoint the root cause of the chain slipping off your Stihl pole saw and take the necessary steps to fix it swiftly.

Precautions to Take Before Fixing the Chain

Before diving into fixing the chain on your Stihl pole saw, it’s crucial to take some precautions to ensure your safety and the effectiveness of the repair. Here are some steps to follow:

  • Turn Off the Saw: Before doing anything, ensure the saw is powered off to avoid any accidents.
  • Let it Cool Down: Give the saw some time to cool down, especially if it has been in use recently.
  • Wear Protective Gear: Put on gloves and eye protection to safeguard yourself from any sharp edges or debris.
  • Inspect the Area: Make sure the work area is well-lit and clear of any obstacles.
  • Refer to the Manual: Consult your Stihl pole saw manual for specific instructions on chain maintenance.

By following these precautions, you set yourself up for a smooth and safe chain-fixing process.

Tools You Will Need

When putting the chain back on your Stihl pole saw, having the right tools on hand is essential. Here are the tools you’ll need to complete the task efficiently:

  • Pliers: To help with gripping and maneuvering small parts.
  • Screwdriver: For adjusting and securing parts of the saw.
  • Bar and Chain Oil: To lubricate the chain for smooth operation.
  • Wrench: For tightening or loosening bolts as needed.
  • Work Gloves: To protect your hands during the process.

Having these tools ready before starting the chain reinstallation process will make the job easier and more manageable.

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Step-by-Step Guide to Putting the Chain Back on Your Stihl Pole Saw

When it comes to putting the chain back on your Stihl pole saw, it’s essential to follow a systematic approach to ensure a smooth reinstallation process. Here is a step-by-step guide to help you get your saw back in working order quickly:

  • Step 1: Prepare Your Workspace

  • Find a well-lit and spacious area to work on your Stihl pole saw.
  • Lay down a clean surface like a workbench or table to prevent any small parts from getting lost.
  • Step 2: Check the Chain Tension

  • Ensure that the tension on the chain is adjusted correctly to prevent any issues during reinstallation.
  • Step 3: Loosen the Bar Nuts

  • Using a wrench, carefully loosen the bar nuts to release the tension on the chain.
  • Step 4: Place the Chain on the Bar

  • Carefully place the chain back onto the bar, ensuring it sits snugly in place.
  • Step 5: Adjust Chain Tension

  • Adjust the tension on the chain as per the manufacturer’s guidelines for optimal performance.
  • Step 6: Secure the Bar Nuts

  • Once the chain is properly in place and tensioned, tighten the bar nuts securely to hold everything in position.
  • Before using the saw, do a quick test to ensure the chain is running smoothly and there are no issues.

Following these steps will help you effectively put the chain back on your Stihl pole saw and get back to your yard work in no time.

Testing the Chain and Final Checks

When testing the chain on your Stihl pole saw, ensure the chain tension is adjusted correctly. You can do this by tugging the chain lightly—it should move smoothly along the guide bar.

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After placing the chain back on the bar, rotate the chain manually to check for any twists or kinks. These can cause the chain to jam during operation, leading to potential damage.

Don’t forget to double-check that the bar nuts are securely tightened to prevent any accidents while using the pole saw. Loose nuts can result in the chain coming off unexpectedly.

For your final checks, inspect the entire setup of the chain on the saw. Confirm that everything is in place and properly aligned before starting the saw to ensure a safe and effective operation.

Important Tips:
Chain tensioning: Tug the chain lightly to ensure it moves smoothly.
Check for twists: Rotate the chain manually to spot any twists or kinks.
Securely tighten: Double-check the bar nuts to avoid accidents.
Final inspection: Confirm everything is aligned for safe operation.


Now that you’ve gone through the steps of putting the chain back on your Stihl pole saw, you’re all set to tackle your next cutting project with confidence. Remember to double-check the chain tension, ensure it’s correctly placed on the bar, and tighten those bar nuts securely. By following these guidelines, you’ll not only maintain the efficiency of your pole saw but also ensure your safety while using it. Keep these tips in mind each time you need to reassemble the chain, and you’ll be able to enjoy smooth and effective operation every time. Happy cutting!

Frequently Asked Questions

How do I prepare a suitable workspace for reassembling the chain on a Stihl pole saw?

Ensure the workspace is well-lit, flat, and spacious enough to move around. Lay down a clean surface like a workbench or table to prevent any parts from rolling or getting lost.

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How do I check the chain tension before placing it on the bar of the Stihl pole saw?

Hold the chain with gloves and pull it at the center of the bar to check for proper tension. It should snap back with light tension and not sag underneath the bar.

What is the correct procedure for placing the chain on the bar of the Stihl pole saw?

Start by placing the chain over the bar with the teeth facing forward and pointing down towards the motor. Make sure the drive links fit into the bar groove.

How do I adjust the tension of the chain on the Stihl pole saw after placing it correctly?

Use the tensioning screw or knob on the side of the bar to adjust the tension until the chain sits snugly on the bar without sagging underneath.

Why is it important to test the chain for correct tension after assembling it on the Stihl pole saw?

Testing ensures that the chain is properly tensioned to prevent accidents like kickbacks or chain derailments during operation.

What should I check for after assembling the chain on the Stihl pole saw to ensure smooth operation?

Check for any twists or kinks in the chain that may hinder its movement along the bar and cause issues during operation.

How can I securely tighten the bar nuts after placing the chain on the Stihl pole saw?

Use a wrench to tighten the bar nuts while holding the tip of the bar to prevent it from moving and ensure the chain remains in place.

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What final inspection should I conduct to ensure safe and effective operation after reassembling the chain on the Stihl pole saw?

Inspect the chain tension, bar alignment, and overall assembly for any loose parts or abnormalities before starting the pole saw for operation.

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Jackson Hill is a passionate arborist with years of experience in the field of trees. He developed his fascination with trees at a young age, spending countless hours exploring the forests and climbing trees. Jackson went on to study arboriculture and horticulture at Michigan State University and later earned a degree in forestry from the University of Michigan.

With his extensive knowledge and expertise, Jackson has become a trusted authority on trees and their impact on the environment. His work has helped shape the field of arboriculture and he continues to be a leading voice in the industry.

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