If you’re a woodworker, chainsaws are one of your most important tools. Stihl is a popular chainsaw brand and is known for its power and efficiency. If your Stihl chainsaw keeps breaking, what could be causing this?
Your Stihl chainsaw cords are breaking due to incorrect handling, poor chainsaw cord quality, or a damaged rope guide. The problem could also be because of a sharp recoil or insufficient tension in the spring.
This article will explain these causes in detail and will provide some useful fixes. Let’s get started!
1. Incorrect Handling
If you don’t handle your chainsaw as outlined in the user manual, you risk damaging the cord. Before using your Stihl chainsaw for the first time, it’s worth reading through the manual and familiarizing yourself with the best way to use it.
Here are some examples of actions that can cause your chainsaw cord to break:
- Incorrect pulling: Some chainsaw users pull the cord too far at one end. You should avoid doing so as it can cause the chainsaw cord to snap and break.
- Releasing while taut: If you release the cord while still taut, it will increase the risk of snapping.
- Yanking the cord: If you yank the cord before the slack is up, the cord may break. The gear will hook into the flywheel, setting it up for damage.
How To Fix
Handle your chainsaw according to the instructions in the user manual. Doing so will ensure that your chainsaw cord lasts for many years.
If you don’t like the idea or reading through a boring user manual, consider watching a YouTube tutorial. The video below shows you how to operate and maintain your chainsaw correctly:
2. Poor Chainsaw Cord Quality
Unless your chainsaw has a manufacturing defect (which is incredibly rare), the original cord should last you for several years before needing to be replaced. If you have recently replaced the chainsaw cord with a generic one, the reason for breaking could be due to poor quality (source).
How to Fix
If you need to replace your chainsaw cord, buy an original Stihl part. Although this might be more expensive upfront, it will save you money in the long run.
If you’re unsure where to get a cord, visit a Stihl service center for help. You can find the nearest dealer via the Stihl Dealer Locator Site.
3. Damaged Rope Guide
The chainsaw rope guide is an important part of your machine because it provides balance and direction for your cord. Your rope guide can experience wear and tear over time. This can affect the chainsaw cord and cause it to break.
You may not know the fault comes from the rope guide unless you evaluate it thoroughly. To find the rope guide, consult your chainsaw’s user manual.
How To Fix
If you have a damaged rope guide, it’s best to replace it with an original Stihl part. You can take it to a professional for replacement, or you can replace the rope guide yourself. The YouTube video below explains how you can replace the starter rope in a few easy steps:
4. Sharp Recoil
Sharp recoil in a chainsaw can lead to cord tears and cause it to break. The recoil on your chainsaw should be soft to reduce wear and tear because a sharp recoil doubles the wear and tear rate.
How To Fix
The good news is that you don’t need to replace a sharp recoil – you can fix it. Here’s what you need to do:
- Loosen the fuel tank. The recoil is located underneath it.
- Clean the recoil. It’s normal to find dirt or dust on it. Clean it with a damp rag and remove any visible debris.
- Smoothen any sharp edges. You can do this by hand trimming, filing, or sanding them.
- Replace the fuel tank. Reassemble your equipment and store it until you’re ready to use.
- Insufficient Spring Tension
Another cause of a Stihl chainsaw cord breaking more often than it should is insufficient tension in the spring. When the chainsaw cord is too slack, it increases the risk of becoming nicked, torn, or damaged but thankfully this is simple to resolve.
How To Fix
To fix a slack cord, you should follow these steps:
- Remove the guide bar nuts, and unlock the chainsaw’s brake.
- Take off the side panel and use a screwdriver to tighten the tension screws on the guide bar.
- Replace the side panel and check if the tension is suitable.
How To Replace a Stihl Chainsaw Cord
If your Stihl chainsaw cord is broken, you can replace it yourself or enlist the help of a professional.
If you’ve decided to replace it yourself, below is a helpful guide:
- Open the fan housing on the right side of the chainsaw to access the rewind pulley (source).
- Use pliers to pull the spring pulley and remove the rotor from the starter post.
- Using a screwdriver, release the round cap from the starter cord handle. You will now have access to the rope. Untie the rope and remove it from the handle.
- Get the replacement rope and tie a knot on one end. Put the other end through the handle.
- Push the free end through the hole in the fan housing and the pulley. Tie another knot to secure the rope.
- Replace the pulley on the starter post, turning it back and forth to hook the rewind spring.
- Reassemble the spring clip on the starter post, and position the clip in a clockwise position.
- Turn the pulley in a clockwise position six times to supply tension to the rewind spring. Then, release the pulley. The rope will coil on its own. You can now replace the fan housing assembly.
Have you ever faced the problem of your Stihl pole chainsaw stopping when cutting? Check out my guide to learn why it happens and how to solve it.
Final Thoughts
Your Stihl chainsaw cord may keep breaking due to abrasion from a sharp recoil or a damaged rope guide. Incorrect handling and a poor quality, non-Stihl cord replacement can also be a cause.
By following the tips above, you can solve the issue of your Stihl cord breaking too often.
