A chainsaw without power is a pretty inefficient tool, so if you’re trying to use your Stihl chainsaw and it won’t spark, you’re likely to seek a solution immediately. Fortunately, fixing a chainsaw without a spark is doable on your own.
You need to replace the ignition module to fix a Stihl chainsaw that doesn’t have a spark. Replacing the ignition module is a matter of removing all the necessary covers, taking out the old module, and inserting the new one.
In the rest of this article, I’ll explain some symptoms you should look out for that indicate a need for an ignition module replacement. I’ll also tell you how to replace this module and all the necessary gear and tools you’ll need.
Signs That You Need to Replace Your Ignition Module
A chainsaw is a potentially dangerous tool to work on with potentially lethal voltage, so before you start tinkering with it, you should make sure that the ignition module is at fault and needs to be replaced. Here are the symptoms of a bad ignition module:
- You don’t have any spark at all. This is probably the sign that brought you to this article. If you can’t get a spark at the spark plug, this is a clear sign that something is wrong with the ignition, and you’ll need to work on the ignition module.
- The chainsaw only works when it’s cold. Sometimes a Stihl chainsaw doesn’t stop working completely, but it runs well when it’s at a cold temperature and stops working when it warms up. If this is the case, you might be able to let the saw cool down and start using it again, but this is time-consuming and inefficient.
- The electrical system is working. Another potential cause for a Stihl chainsaw failure is a faulty electrical system. However, if you check the electrical system and find that it is working properly, the ignition is the problem.
To check the electrical system on your saw, disconnect the positive wire from the coil and check to see if you have a spark. If you don’t, the ignition is the problem. If you have a spark once the coil is disconnected, your chainsaw may have an electrical problem (source).
How To Replace an Ignition Module for a Stihl Chainsaw
Now that you’ve determined you need to replace your module, let’s explore how to do this. Follow these steps:
1. Dress the Part
Safety first! When working on a tool, you must dress appropriately to avoid injury. Stihl chainsaws have potentially lethal voltage, so you must be careful (source).
According to the Occupational Safety and Health Administration (OSHA), when operating a chainsaw, your protective equipment should include head protection, eye protection, hearing protection, and suitable footwear. I also recommend following these safety protocols when working on a chainsaw. You never know what could happen, and it’s better to be safe than sorry (source).
Your eyewear should resist fogging and have an ANSI rating of Z87.1. I like these Malta Dynamics Safety Glasses (link to Amazon). The molded bridge design on these glasses makes them a perfect fit for almost everyone, and the thin-flexible frame stays comfortable on the face, so you can work for longer without your eyewear pinching your nose or ears.
2. Remove the Air Filter Cover, Spark Plug Boot, and Top Cover
The first step of replacing your ignition module is getting access to your ignition, which involves removing all the necessary covers. There are typically two T27 Torx screws holding the top cover in place, so you’ll need the proper screwdriver.
I recommend this AKTOO Torx Screwdriver Set (link to Amazon). This set includes T15, T20, T25, T27, and T30 drivers, so you’ll be able to use the T27 one for this step of replacing your ignition module. I also like how durable these tools are; they’re made with chrome vanadium steel and heat-treated for premium toughness and resistance.
3. Remove the Spark Plug
The next step is to remove the spark plug, and at this point, I recommend checking to see if you can get a spark with a new plug. If the plug is the issue, you can simply replace it and be on your way without having to replace the entire module.
If you check for a spark using a new spark plug and still don’t get anything, continue to the following steps. I recommend purchasing this two-pack of Stihl Spark Plugs (link to Amazon). These plugs are genuine replacements for Stihl chainsaws but also fit with other makes. I also like that they’re designed for long-term usage, so ideally, you won’t have to replace your spark plug again anytime soon.
4. Remove the Recoil
The recoil is attached to the saw with T27 Torx screws, so you’ll need to use a T27 screwdriver to remove it. Once you remove the recoil, you’ll have a full view of the ignition module. You’ll find two more T27 screws you’ll need to remove there.
Once those screws are out of the way, you can remove the wires from the bad ignition coil and take out the coil.
5. Insert Your New Ignition Module
Once you have the old ignition module out of the way, it’s time to turn your focus to the new one. I suggest this Hipa MS251 Ignition Coil Module (link to Amazon). You can use this module in most Stihl chainsaw models, and it is an authentic manufacturer-sourced replacement, so you can be sure it will work in your saw. If it doesn’t, I like that Hipa offers a ninety-day return, refund, or exchange policy.
Place your new ignition module into the saw and attach all the wires. Tighten up all the screws evenly. There should be a gap between the ignition module and the flywheel, so you can use a business card or piece of cardboard to create this gap while inserting the new module.
6. Reinstall the Recoil and Covers
Once you have the new module in place, you need to reinstall the recoil assembly and put all the covers back in their place. Ensure you screw everything tightly, so you don’t lose any parts. Check to see if you can get a spark now that you have a new module. If you’ve done everything correctly, you should be able to get a spark without any problems!
Sometimes you may need to remove a spark arrestor from a Stihl chainsaw. Check out my guide to learn how. You’ll also learn how a spark arrestor works and when to change it.
Final Thoughts
If your Stihl chainsaw doesn’t have a spark, the cause is likely a bad ignition module. To fix this problem, you’ll need to replace the module. Replacing an ignition module involves removing all the necessary covers, removing the old module, and inserting the new one. If you’ve properly installed the new module, you should be able to get a spark without any issues.