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 8nHL 090, 090 AY, 090 G

Congratulationsl Instruction Manual/Owner's Manuals, .

Sharpening and Maintenance of Saw Chains
You are the owner of a precision-manufactured STlHL
chain saw designed to give you long and dependable Contents
service. To receive maximum performance and satisfaction Parts of the Chain Saw 2
from your STlHL chain saw, it is important that you read Satety Precautions 4
and understand the maintenance and safety precautions - The Operator 4
before using your saw. Contact your STlHL Dealer or the -The Saw 6
SllHL Distributor for your area if you do not understand - The Use of the Saw 6
any of the instructions or warnings in this Manual. - Maintaining and Storing the Saw 19
Mounting Guide Bar and Chain 20
This Manual contains warnings regarding your saw, Fuel 22
operating and safety instructions for all STlHL 090 series Chain Oil 22
power saws. Helpers Handle 23
Starting 24
011 Quantity Control 27
Warning I Cutting Attachment 28
Air Filter 30
Because a chain saw is a high-speed wood-cutting tool, Carburetor . 31
some special safety precautions must be observed as with Replacing the Chain Sprocket 32
any other power saw to reduce the risk of personal acci- Gear Lubricant 090 G 33
dents. Careless or improper use may cause serious or Rewind Starter 34
even fatal injury. Maintenance Chart 36
Specifications 37
It is important that you fully understand 'the contents of this Sharpening and Maintenance of Saw Chain 39
Manual and that you allow only persons who understand
this Manual to operate your chain saw.

Pay special attention to the safety precautions and cutting

techniques outlined on pages 4 to 19.

STIHL!s philosophy Is to continually improve all of its pro-

ducts. As a result, engineering changes and improvements
are made from time-to-time. Written notices relating to
such changes are sent to STIHL Dealers. If the operating
characteristics of the appearance of your saw differs from
those described in this Manual, please contact your local Andreas Stihl
STlHL Dealer for updated information and assistance. STIHL~ D-7050 W8lblingen 1
0458 166 0121. MO,7S.AO.1: Printed In West Germany x C 1990 Andreas Stlhl, Walblingen

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 Parts of the Chain Saw

4 Front hand
Guide
5 Front handle bar nose 3

6 tenninal Guide bar 2

of filter cover

Bumper spike 13

9 Clutch l '

O'lain catcher 15

Oil hand Chain 16

12 Oil

22 Chain

23 Choke lever 18

throttle lock 19

25 Slarter throttle lock 20

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 Defil1llfOns 14. ClUtch. C()upJes engine to chain sprocket when
engine is accelerated beyond Idle speed.
1. Oilo~ Saw Chain. A J09P ~ of cutters.
tie straps ~drive links. . ',' ~,.- 15. Chain Catcher. Catches a broken chain and guides
It inside the chain sprocket COVet
2. Guide Bar. Su_~:ijuJdes the saw chain. ""~~~~\'
. ";.,: )"'~: ~:/r~
16. cta8fr. 8prf;K=ket. The toothed wheel that drives the
3. Gu. . ~rNose.:~~,paitoftheguidebar. sawctUll~ .
4. ~ ~auarii.-~.::\~
~ .,." PI, agafnst Pro.. 17. Chain.Sprock8t Cover. Covers the clutch and the
jecting ~fInd helps prevent the left hand from sproClCet.
touchi
• 0< ,.:,._.,..J!~t
ttcEt Ch8tn if It 'slips
",,-of.. ' ' , ' , ,,,,,
off the handle
,
bar• ,
18. Choke Lever. Eases engine starting by enriching
5. Front Handle. Handle bar for the left hand at front of ~ixlure.
saw.
19. Startfng Throttle Lock. Keeps the throttle partualJy
6. Sp;idc Plug TemdnaL Connects the spark plug with ~n ~ring starting.
1he i9nHiOn Wire.
20. ~ Throttle Look. Must be depressed before
7. Lock'or-Filter Cover. For remoVing filter cover, per- ~ the throttle trigger.
rnitS1Uter to.be cIearied.:
21. Throttle TrIgger. Controls the speed of the engine.
8. ,Rear'Handle-The Support handJe for the right hand,
. Iocited at or tOward the rear of the saw. 22. ChaIn Guard (Scabbard). Protects the operator from
touchil1$1 the chain.
9. Oil Fftier ~For closing the 011 tank.
23. Decompfession Valve. Makes starting easier.
10. Stop Switch. Switches the engine's ignition system
off and stops the running of the engine. 24. Muffler. Attenuates exhaust noises and diverts ex-
haust gases i~, req~lreQ ~on.
11. Oil Hand Pump. For additional manual c::;haln lubri-
cation.. 25. Starter ~'The, grip Of the, pull ,starter. which is the
device to start the engine.
12. 011 Inspection WIiu:Iow. For contrO'mng the chain 011
level. 26. Fuel FlUer Cap. For closing the fuel tank.

13. BUmper ~ Toothed stop for holding saw steady

againSt wood. 3

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 Safety Precautions

The use of any chain saw may be hazardous. The saw chain Bystanders, espedally children and anim~s should .not be
has large, sharp cutters. If the cutters contact your flesh, allowed in the area where a chain saw is in use (ill. 1).
they will cut you, ewn H the chain,
is not m9VIns.' At full Never letlt\e saw run unattended. $.Ore it in a locked place
throttle, the chain speed can reach 45 mph '(20 ri1Is). It is away from 'Children and empty the fuel tank before stonng
important that you read, fully understand and observe the a
for longer than few days. . .
following .safetY precautions and .warningS. ;Read the Do not lend Y'0ur chain saw without the Owner's Manual.
owner's manual and the safety' inStructions periOdically. Be sure that 'anyone' 'using ,yO~'saw understands the
Pay special attention to the section on reactive forces, information contained in this Manual.
pages 10 to 13. These safety precautions and waqlings apply to the use of
all STlHL ~n saws. Different ~odc$ may have ~erent
Warning! parts and controls. See the 'appropriate section of your
Reactive forces, including kickback, can be dangerous. Owner's Manual for a description of the controls and
Careless or improper use of any chain saw may cause
serious or fatallnjuiy. . ' ,.
function of the' p8rts of your modelsaw.
All safety precautions that are generally observed when Safe use of a chain SaW involves
working with Bnaxeor a'hand saW aisoapply ~ the'opefa- t the operator
lion of chain saws. HOWever; beCause '8 Chain saw is a 2. the saw
hlghspeed, fast cutting power tool,~a1 safety pre- 3. the uSe of the saw.
cautions must be obSerVed to reduce ,tti~~ risk of personal
accidents. .- . THE OPERATOR
Have your ,STIHL dealer show you how to operate your
chain saw. ObserVe all appllCabra'~ safetY 'regulations, Physical Condition
standards and ordinances. You must be in good physical condition and mental health
,Warning! and not under the influence of any substance (drugs,
4 Minors should never be allowed to use a chain saw. alcohol), which might impair vision, dexterity or judgment.

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 Do not operate a chain saw when you are fatigued (UI. 2).
Be alert .:.. H you 'get tired while operating yOlir ctiain saw,
take. a ~r~ak. tiredness may result ,in .1oSs~f co~.
Working vVith aity,chaiO saw. can De 'Strenu()us. If you have
any .conditiOn tfiat inight .. be aggravated by 'strenuous
work. check with your doctor befOre operating a chain saw.
~!
PtoIonged.~ ofcl1ain saws (or other m~ines) exposing
the operator to vibrations may produce Whitefinger dis-
ease (Raynaud's phenomenon). This phenomenon redu-
ces the hand's ability to feel. and regulate temperature,
produces numbness andburriing sensations and may
• cause nerve and circulation damage and tissue necrosis.
MinySTIHL models are' available with an anti-vibration
system designed to reduce engine 'vibration. An anti-
vibration system is recommended for those using chain
saws on a regular or sustained basis.

Heated handles help to reduce the risk of Whit8finger

disease and are recommended for cold weather use. Most
STlHL Powerheads are available with heated handles.

Anti-vibration sYstems and he~ecI handles do not gua-

rantee that you will not,sustain Whitefinger d"lS8ase~ There-
fore continual and regular users'should 'monitor clOsely
.their use of chain saws and their physical condition. Good footing is most Important in chain saw work. Wear
sturdy boots with nonslip soles. Steel-toed safety boots
Proper Clothing . '. are recommended. . ," >.
CIOthil1Q 'musfbe stUrdy and snug-fitting. but allow c0m- Proper eye protection Is a must. Non-fogging, vented
plete fieedom of' movement. AvOId Ioose-fitting jackets, goggles or a.face screen is recommended. Their use
~ ~.jeweirY. ~ or~ pants, or anYthing reduces the risk of eye injury. " "

p.
that could become entangled with the saw or brush. Wear
ove~~ o~ jeans with' a reinforced cutting resistant insert
(Ill 3). , . .
your hands with gloves when handling saw and
saW chain. Heavy-duty, nonslip gloves improve your grip
and protect your hands.
Wear an approved safety hard hat to protect your head.
Chain saw noise may darriage your hearing. Always wear
sound barriers (ear plugs or ear muffters) to protect your
hearing.
Continual and regular users should have ·their hearing
checked regularty. 5

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 must be stopped and the saw must be in the proper position.
Grip ~e front handle and place the muffler at the 'side away
from the body (i1l.4). " .
1tl8' c;hafn -guard (scabbard) ~Uld tie over the chain and
the gu~ barWhfCh ~rd P9fljt b8ckwards. When carrying
your ~ ~ barsttould be behind you (i1l.4).

By vehicle: When transporting in a vehicle, keep chain

EiI19bar, ~v~red with the ch~n.guard., Properly ,secure
your saw
to prevent turnover, fuel SpHlage and damage to
the saW. " .
4

Prepaf8tion forihe use of the saw

THE SAW
T~ off the chain guard and inspect for safety in operation.
Parts of the chain saw; Illustrations and definitions of the For assemblY
please foUow ~ procedure described at
parts see pages 2 and 31 the appropriate section "Mounting the Bar and Chafn" of
your owner's Manual. '
~I
NevermodHy a chain saw in any way. Only attachments STlHb-Oilornatic chain, guide bar and sprocket must match
supplied by STlHL or expressly appro~,!)y STlHL ,for eaCh other:' ' " . ."
use with the specific STlHL saw modelS ,are. authorized. If the, g~i48 ~r 'or chain Is ~1aC8dt it must be with a bar
Although certain unauthorized attachmentsaie useable or Ch8In of the same type. ReplaCement with another type
with the STlHL powerhead. their use may, in fact, .be of guide bar or chain 'wiD seriously increase the 00,ances ,of
extremely dangerous. ' ope~ iF.ljury ~ue t() the Contact of the 'moving chain with
.~ operator during n;rtational kicIcb8ck.
THE USE OF THE SAW
W8rnirig!
TranSporting the chain saw Proper tension of the chain is extremely important. In order
to av~ ~ .setting the tensiol1ing ~we must 'be
W8ming! fot~ as, d~ in Y9ur ~"'M~,~ys ~re
AJW8yS Stop the enQtne before'pUtting a chain saw down or ~h,e*agoraarn~s>'fotthesp~coveriS(~)~
carryi~ ~. ~ ~ .chain' sti~;with ~' engine running seCuteJy after tensioning, ~e .chaffL CheCk Chain t~n
is extteinely dangerous. 'A'CCidentaJ acceleration of the once'~ after t:taving. tigtlte.ned the n~ and thereafter
engine eancsuse the chain to rotate. Avoid touchmg the at regular intervals (Whenever the saw is shut off). If the
hotmUffter.' . .~ . chain becomes loose while cutting, shut off the engine and
then tighten. Never try to tighten the chain while the engine
6 By hand: When carrying your saw by hand, the 'engine is runningl

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 5 6

Fueling Starting
- Your STlHL chain saw uses an oll-gasoline mixture for fuel
(see chapter" Fuel n of your Owner's Manual). Wamlng!
Your chain saw is a one-person saw. Do not allow other
Warning! persons to be near the chain saw. Start and operate your
Gasoline is an extremely flammable fuel. Use extreme saw without assistance. .
caution when handling gasoline or fuel mix. Do not smoke
or bring any fire or flame near the fuel (ill. 5). For safe and specific starting Instructions. see the appro-
priate section of the Owner's Manual.
Fueling Instructions
Fuel your Chain saw in well-ventilated areas, outdoors Do not drop start. This method is very dangerous because
only. YC?':I maY.lose control of the saw (ill. 6).
Always shut off the engine and allow It to cool before
refueling. Relieve fuel tank pressure by loosening fuel cap Place the chain saw on finn ground or other solid surface in
slowly. an open area. Maintain a good balance and secure footing.

Select bare ground for fueling and move at least 10 feet Be absolutely sure that guide bar and chain are clear of you
(3 m) from fueling spot before starting the ~ngine. and all other obstructions and objects, including the
ground: because when the engine starts at starting-
Wipe off any spilled fuel before starting your saw and throttl~, engine speed will be fast enough fOr the clutch to
check for leakage. engage sprocket and tum the chain, which may cause
kickback to occur.
Check for fuel leakage while refueling and during operation.
If fuel or 011 leakage is found, do not start or run the engine Engage the chain brake when starting a QuiclCstop model.
until leak is fixed and spilled fuel has been wiped away. (see chapter "Chain Brake" in your Owner's Manual). 7

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 Never attempt to start the saw when the guide bar is in a
cut or kerf.

When you pull the starter grip, don't wrap the starter rope
around your hands. Do not allow the grip to snap back, but
guide the starter rope slowly back to permit the rope to
rewind properly. Failure to follow this probedure may result
in injury to hand or fingers and may damage the starter
mechanism.

7
Important adjustments

Warning! At correct idle speed, chain should not turn. Warning,! Avoid stumbling on obstacles such as stumps,
For directions to adjust idle speed, see the appropriate roots or rocks and watCh out for holes or ditches. Be
section of this Owner's Manual. extremely cautious when working on slopes or uneven
ground. There is increased danger of slipping on freshly
Do not use a saw with incorrect idle speed adjustment. debarked logs. .
Adjust the idle speed your..self according. to the' appro-
priate section of this manual.
Cutting Instructions
Have your STIHL Dealer check your saw and make proper
adjustments or repairs. . Grip: Always hold the saw firmly with both hands when
.. the engine is running. Place your left hand on front handle
After adjusting a chain start the saw, letthe engine run for a bar and your right hand on rear ,handle and throttle trigger..
while, then switch engine off and recheck chain tension. Left-handers should follow this instruction too.
Proper chain tension Is very important at all times.
Wrap your fingers tightly around the handles, keeping the
Working COl\dltlons handles cradled between your thumb and forefinger (ill. 7),
With your hands in this position, you can best oppose and
Operate your chain saw only outdoors in aventilated area. absorb the push, pull and kickback forces of your saw
Operate the saw under good visibility and daylight condi- without having it slip out of your grip (see section of reactive
tionsonly. forces). Make sure your chain saw handles and grip are in
good condition and free of moisture, pitch, oil or grease.
Warning! Take extreme care in wet and freezing weather
(rain, snow, ice). Put off the work when the weather is Wamlngl'Never use the saw with one hand. You cannot
.windy, stormy or rainfall is heavy. Clear the area where control reactive forces (see pages 10 to 13) and may lose
8 you are working. control of the saw.

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 warning! Do not operate your chain saw with starting
throttle. Cutting with starting throttle does not permit
the operator proper control of the saw or chain speed.

Wamingl Never touch a rotating chain with your hand or

any part of your body.

Wamlngl

Do not cut any material other than wood or wooden objects.

Use your chain saw for cutting only. It is not designed for
prying or shoveling away limbs, roots or other objects.

When sawing, make sure that the saw chain does not touch
any foreign materials such as rocks, nails and the like (ill. 8).
Such objects may be flung off, damage the saw chain or
cause the saw to kick back.

In order to keep control of your saw, always maintain a

firm foothold. Never work on a ladder, In a tree or on any
other insecure support. Never use the saw above shoulder
height (ill. 9).

Position the chain saw in such a way that your body is clear
of the cutting attachment whenever the engine is running.
Stand to the left of cut while bucking (see ill. 10).

Don't put pressure on the saw when reaching the end of a

cut. The pressure may cause the bar and rotating chain to
pop out of the cut or kerf, go out of control and strike the
operator or some other object. If the rotating chain strikes
some other object a reactive force (see pages 10to 13) may
cause the chain to strike the operator.· 9

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 Reactive forces during the cut, including kickba-*
WARNING!
Reactive forces, that may occur during any cut are kick-
back, pushback andpull-in. Reactive forces ·can ··be
dangerous! In any chain saw, the powerful force used to
cut wood can be reversed (and work against the operator).

If the rotating chain is suddenly stopped by contact with

any solid object like a log or branch or is pinched, the
reactive forces Instantly oCcUr. These reactive forces may
result in loss of control which may, in tum, cause serious
or fatal injury. Anunderstaiidin~i of the cauSes of these
reactfveforces may help you aVoid loss of control.

The most common reactive forces are

':"ldckback,
-pushback,
-pull-in.

Kickback:
Kickback occurs when the upper quadrant of the bar nose
contaCts a solid object in· the woOd Or is pinched (III. 11).
The reaction of the cutting force of the chain 'causes a
rotational force of the chain saw'in the directidn Opposite
to the chain movement, mainly in the plane of the bar. This
may fling the bar in an uncontrolled arc mainly in the plane
of the bar.

Under some circumstances the bar ·moves towards the

operator who may suffer severe or fatal injury. It may also
occur during limbing. It also occurs when the nose of the
guide bar is pinched unexPeCtecDY, unintentionally
contacts sorld material in the wood (ill. 12) or is Incorrectly
used to begin a plunge or bOring cut.

The greater the force of the kfckb8ck reaction, the more

10 difficult it becomes for the operator to controf the saw.

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 .... ..- ~ .
Many factors influence the occurence and force of the operatOr's left hand is gripping the froI1t hBrldle behind the
!kickback reaction. The ~ of bar and saw chain you ~ hand guard, and if the left hand rotates around the front
~ is a factor in the force of ttie-klCkback reaction. handle and contacts the front: hanef guard, which is the
,Quickstop activating lever,. this contact will activate the
;The speed of ~ ~wh" the cutter contacts the . Quickslop and,~ the;chaln'(~ ill 13). '
object. .,' _ ~" <.~, ),' -'_'. ". -
,Kickoaclfforces'Inereuewlth the raleOf Impact·
','
\The ~.brake of some STlHL chain saws is additional
. self-activated by fnertia.· see appropriate. ct1apler "ChaIn
il > \::..: _"M~: ,'i- ~ ''''-''f

~_ct~~ u.; ~ose of the b,ar and the Brake"dt yo~r <?wner's ManuaL ', ,
~fo.~·{see-IIt-11).'.- ': ,.: ' ".'
KickbaCltVmosfproriOunc:ed '"1M upper quadrant of the , Kickback tendency increases as the radius or size of the
~bar ROSa, ,,'.' guide bar, noseAncreaseLSTIHL has developed guide
bars with small nose radius. These bars. are designed to
reduce the kfckback tendency and are available, as an
SOme STlHL chain types are designed to reduce kickback option.
forces.
STlHL taas~ d~~ chains whoseconftgu,r~ are
The.cJeptb.aauges:' ~ned.to reduce.~ forces. These. chains are
Improper lowering of the depth gauges also Incre~ the available as an option. .
chanceofa~
:1 Warning!
The sharpening condition: Chain saw kickback may cause serious or fatal 'injury. To
warning! reduce the risk of kickback injuries snHL'recommends
Adun orimproperty sharpen.ed ~ may Increase the risk that you equip your saw·Withanarrow),ose bal, lOW profile
of kickback. Always cut with a property sharpened chain. chain or oth8r chatn deSIgned to reduce 'kickback forces,
.. ~aS11HL~.
",

Devices for reducing the risk of Idckback Injury Warning I

~o Qulcksk;Jp or ch~ ~ de~ .prev&n!SkIckback.
STlHL has developed a chain stopping system to reduce These devices are designed only to stop the chain. if acti-
the risk of injury In certain kickback sItuations.Jt ~ called a vated, in.certain kickback situations.
Quickstop.
"" ., In ~r for the Quickstep to reduce the riSk of 'kiCkback
The, ,Quickstopis, av-.i~ as an optiQn on most STIHL inj~, it mUst be P"'~ mai~ anei'ln gOod working
chain.saws. ' . order. In addition, there must be enough distance between

Wti. a~ oc:curs the guide.bar may iotate around

the front handle. H the cutting position Is such that the
the bar and the operator to ensure that the Quickstop has
sufficient time to activate and stop the chain before poten-
tial contact with the operator. ' 11

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 13

Warning!- 6. Begin cutting and continue at fuU throttle.

Even if your saw is equipped with a Quickstop, a n8J'l'OVl
nos.e _~ or ~uced kickback chain, this does not guaran- 7. Cut only one log at a time.
tee'th8t'you '!III not be Injuied by kfcftback,~and therefore
always- observe aU safety prec8utlons to avoldldckback 8. Use extreme caution when re-entering a-previous cut.
, • >

situations.
~

9. Do not attempt plunge cuts (see page 18) if you are not
To avoid kickback experienced with theSe cutting techniques.

The best' protection -from perSonal injury that may result 10. Be alert for shifting of the log or other forces that may
fromkickback·
. Is to avoid I<k:kb8Ck Situations:
, '~
cause the cutto close arid pinch the chain.
1. ~kI the chain saw firmly with both hands andlnalntain 11. Maintain saw chain properly. Cut with a correctly shar-
a secure grip. pened, properly tensioned chain at all times.

2. Be aware of1he location Of the guide bar nose at aU 12. Statid to the side of the cutting path of the ch8Jn saw.
timeS. -':'
3. Never bring the nose Of the guide bar In COntactwfth any Pusliback:
. ~bject. Do not cut limbs with the nose of the guide bar.
. Be'~DIhi
~.'.1 car8fulWhti
.smalftb'
. ug h'nmbS. sman SIze ~hback occurs when the chain on the top of the bar is
, brustf
.
antf'saplIngs which
~.- ,,'."
may eaSily. catch the chain.
~',
suddenly stopped when Ills pInChed. caughforencounters
a foreign object in . . wood. The reaction of the chain
4. Don't overi8ach. i_ drives the saw straight back toward the operator causing
loss of saw cOntrol. PUshback frequenttyoccws when the
12 5. Don't cut above shoulder height. top of the bar Is used for cutting (see 111.14).

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 WBmlngf
Use extreme .caution when cutting small size brush and
sapOF.'9$.'whfch m~y easily catch the.chafn and pull you off
balance. '.

To aVoId pu~1n ',' ... ' _",,','

1. ~ St$rt'a cut with 'the Ci1aJn rotating at full speed
and the bumper SpIk8'~,COhtactwlth 1he wood.

2. PuU-in~8ISo~pre~~~:~~:_toopen
the kerf Or cut. -' '

_' To 8VoIcI puShback

1. Be alert to forces or situations that may cause material
to pinch the top of the chain.
Femng is, cuttll'I9 down a tree.
2. rlc? notcut~reth~ one log at a time. ' ,
Before femng a tree, consider carefully afl conditions which
3. Do not twist the • when withdrawing the bar from a may affect the direction of fall/including:
plupge cut or und8r~ cut (figures 25 to 'Zl and 33,
pageS 16, 17 and 19),' becaUse the chain can pinch. The intended direction of the fall.
'. ,
The natural lean of the tree.
Any MOusuallyheavylimb atru.cture.
Surrounding trees and obstaQles.
Pull-ln: The wind direction and speed.

PuU-ln occurs when the chain ,on the bottom of the bar Is
suddenly stopped. The,chain on~8 bottom oUhe bar stops Warnlngt
when it is pinched, caught or encounters a foreign object
In the wood (see HI. 15). The reaction of the chain pulls Always observe the general condition of the tree. Look for
the S(lW forward, causing Ute operator to Iotle control. decay and,rot in the trunk-If iUs rotted inside, it could snap
and faD toward the operator while being cut.
Pull-4n.frequently occurs when the buR.per sPIke of the saw
Isnot.I)eId,secureIy against the tree or limb and when the Also look for broken or dead brandies which could vibrate
chain is not'rotating atJuU speed before It contacts the loose and fall on the operator. When felling on a slope. the
wood. operator should stand on the up-hiIJ side Hpossible. 13

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 When felling in the vicinity of roads, railways and power Felling Instructions:
lines, etc.. take extra precautions (see ill. 16). Inform the
police, u1ifity company or railway au1hority before begin- Firs1 clear the tree base and work area from interfering
ning to cu1. limbs end brush and clean its lower portion with an axe
(ill. 18). .

When felling, maintaJn a distance of at least· 2'h tree Then, establish.a path of escape and remove all obstacles.
lengths from the nearest person (see ill. 17). This path should be opposite to the planned'dlrection of the
fall of the tree end at a 4S. angle (ill. 19). An alternate
path must also be selected. Place all tools and equipment
Note: a safe distance away from the tree, bu1 not on the escape
14 The noise of your engine may drown any warning call. path.

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 20

H ttle.~,,~ large ~ ~ cut Into the largest

. - .~utbeSSes vertically; first, (hori,zontally next) and remove
(Hl20~ ,,;

~ d8t8rmiil8, the placement of the.feUIng note." (Ul2t).

1J1e'~ ~ ~ ,poper:tY ,placed determ1r)es the

to the nne Of f8n &net shOUld be.

directioh In whJchthe treewiiUaLIt Is made perpendicular
close to the groUnd as
possible. Cut the felling notch to a dePth of abOut one-fifth
Hinge

Felling notch
---i~

to one-fourth of the trunk diameter (Ill 22). It should be

In no ~ higher than it is deep. Make the felling notch 22 -*
very carefully.

Begin the felUng cut slightly higher than the feDing notch
and.ora the opppsite side of tIMI tn!e (ill. .22). Then cut
ho~l)I~h:toward$ ~ ~,n,g notch. Apply the Hinge......,........,H
chab1 saw with its spikes dlrecdy t;MlhIndthe ~ portion
of wood and cut toward the notch (ill 23~ Leave approx-

(III. 23}.'Ofi'i1ot Cut thrOugh the hinge _use you

imately 'ho .o1.the ~ dlam_~ ~n.c;ul This is the hln.ge
Could
lose control of the direction of the faIL Drive wedges into
Felling notch

the felfll'l9. ~t ~ ~ to COI1tmI the direction

oftha ftdl.W~es should be ofw9Qd. Ught alloy or plastic-
never ~'~ Which can ~ kIckback,and ~
tothechala 15

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 24 25

A'iways keep to the side of the f8Jling tree. When the tree Forthe tteeHOriing methOd (HI. 24) make the first cut with the
starts to fall, shut off the engine. WIthdraw the bar and walk guide bar fanning tn toWard the· hinge. Then,usmgthe
away on the pre-planned escape path. Watch out for failing bumper spike as a pivot, reposition the saw for the next cut.
limbs. Avoid reposftioning the saw more than necessary. When
r8poSltiori!rig fci the 11Et~ ~ ic8ep 'the guide ~r .i¥!Iy
Warning! : engaged in the kerr to keep the fettlng cut strafght If the
Be extremely careful with partially fallen trees which are saW begins to pinCh. inSert a w8dge to open the cut. On the
poorly supported. ~ cut. dO not cut the hinge.'
When the tree h~;or 19r ~ other reason does not
fall' completelY, set"the saw asfde'and pull the tree down
with a cabIe·wlnch,btockand tackle or tJactor.lf you try
to cut it down with your saw, you may be injured. Plunge-Cut ~

Tmber haVIng a diameter more than tWice the !ength Of

the gUKJe bar reqUires the use of the plunge-(x.it method
Sectioning Method before making th.e f8lHngcUt ..

warning! First. cUt a large. wide nOtch. Make a plunge- cut In the
a
. Felling a tree that has diameter greater than the length center of the notCh. . ..
of the guide bar requl~ use of either the sectioning or
plunge-cut method. These methods' are extremely The- plunge cut is made with the guide' ~ nose. BegIn
dangerous because they InvolVe the use of the nose of the plunge. cUt by 'applylitg the lower portiOn of the guide
the guide bar and can result In kickback. Only property bei nose to the tree at an angle (ill. 25)~ Cut until the dePth
16 trained professionals should attempt· these techniqueS. of the kerf Is about the same as the width of the guide bar

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 ~
. \A)
26" ~ 29

(m. 26). Next, align the saw In the direction In which the
recess is to be c u t . " .
WIth the ssw- at fulithrotUe, insert th8 guide bar in the
trunk (II!. 27).
Enlarge the plunge cut as shown In illustration (ill. 28).

warning I
There is an extreme danger of kickback at ttris point.
Extra caution must be taken to maintain control of1he saw.
To make the felting cut, .. follow the· sectlonfng rnettiod
described previously (ill. 29).
H you are inexperienced with a chain saw prunge-cutting
should not be attempted. Seek the help of a professional.

Umbing

Umbing .is removing the branches from a fallen tree.

WBmIngl
There is an extreme danger of kickback during the limbing
operation. Do not work with the hose of the bar. Be extre-
mely cautious and avoid contacting the log or other limbs
with the nose of the guide bar.
28 00 not stand on a log while Ilmblng it - you may slip or the
log may roll. 17 Po

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 Start Umbing by leaving the lower limb$ to support the
log off the ground (ill. 30). Always cut f~ the top of the
limb. Do not underbuckfreely hanging limbs•. A pinch
may result or the limb may fall, causing loss of control.
If a pinch occurs, stop. the engine and remove the saw,
by lifting the limb.

warning!
Be extremely cautious when cutting limbs under tension.
The limb could spring back toward the operator and cause
loss of control of the saw or injury to the operator.

Bucking
Bucking is cutting a log into sections. 4. When cutting small iOgS~ Use 8SaWhorae-(iD. 32). NeVer
permit another person to hold the log. Never hold the log
Warnings! with your leg or.foot.
1. When bucking, do not stand on the log. Make sure the
log will not ron down-hill. If on a slope, stand on the up- 5. Logs under straln,'require sPecial attention to prevent
hill side of the 109 (see Ill. 31). Watch out for rolling logs. the saw trpm pinch1n.g•. The fifst cut·is made on the
compression side to relieve the stresS on the log (see
2. Cut only one log at a time. III. 33~ 34). The bucking cut is thEm made as shown. If the
saw pinches, stop the engine and remove it from the log.
3. Shattered wood should be cut very carefully. Sharp.
slivers of wood may be caught and flung in the direction 6. Only properly trained professionals should work in an
18 of the operator of the saw. area where the logs, limbs Bn.d roots are tangled (i.e. a

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 blowdown area, ill. 35). Worldng in blowdown areas is
extremely hazardous.

1. Refoeving cut 7. Drag the logs into a clear area before cutting. Pull out
exposed and cleared logs first.

Maintenance BDd Repair

Never operate a chain saw that is damaged, improperly

33 adjusted Of not completely or securely assembled. Follow
the maintenance and repair.instructions in the appropriate
section of your Owne~s Manual.

warning!
Always stop the engine and make sure that the chain is
. 2. Cross art stoppe.d before doing any maintenance or repair wor!< or
cleaning the saw. Do not attempt any maintenance or
repair wor!< not described in your Own~s Manual. Have
such work performed at your STlHL service shop orily.

MAINTAINING AND STORING THE SAW

34
Keep the chain, bar and sprocket clean and lubricated;
replace worn sprockets or chains.

Keep the chain sharp. You can spot a dull chain when
easy-to-cut wood beccmes hard to cut and bum marks
appear on the wood.

Keep the chain at proper tension. Tighten all nuts, bolts

and screws except the carburetor adjustment screws after
each use.

Keep spar!< plug and wire connection tight and clean.

Store saws In a high or locked place, away from children. 19

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 Mounting Guide Bar and Chain
Top: Backing off tensioning nut Top: FJtting the Ollomalic chain
Bottom: Locating the guide bar Bottom: Cutting edges face the bar nose

The guide bar and Oilomatic chain are supplied separately Locate slot of guide bar over the stud bolts (2) so that the
for safety reasons. lug of the tensioning nU1 (4) engages in the lower fixing
hole (6).

To mount them, first unscrew the coliar nuts (1) from the
stud bolts (2) and take off the sprocket cover (3). Starting at the chain sprocket, place the Oilomatic chain on
the guide bar so thal cutting edges on the top of the bar are
facing the bar nose (7). Fit chain sprocket cover (3) on the
stud bolts (2) and tighten coliar nuts (1) temporarily by
Now back off the chain tensioning nU1 (4) - below the stud hand. .
bolts (2) - by tuming the tensioning screw (5) counter-
20 clockwise to the end of Its thread.

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 Top: Tensioning the Oilomatic chain
Bottom: TIghten collar nuts securely Checking chaln tension

The Otlomatic chain Is correctly tensioned when is fits

snugly on the underside 01 the bar 1;,"1 can stili be pulled
easily around the bar.

Now tension the Ollomatic chain by tumlng the tensioning

screw (5) ctockwise. making sure that the drive link tangs
are lined up with the bottom groove of the bar. Hold the bar
nose (7) up tum tension screw (5) until the Oilomatlc chain ·
is pmperly seated on the underside 01 the bar. While stili
holding the bar nose uP. tighten the collar nuts (1) securely.

21

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 Fuel Chain Oil

Fuel tank cap open Oil filler cap open

You two-stroke engine is powered by a mixture of gasoline The service I~e of the cutting attachment (Oilomatic chain
and engine 011. andguide bar) depends on'good lubrication and the quality
of the lubricating 011.
Only regular gasoline may be used. Never use high
octane gasoline as it contains benzol which would per-
manently damage the carburetor diaphragms. Never use waste 011 for this pUrPosel

Only use STIHL two-cycle engine oil or other branded two-

cycle engine oils for mixing. The mix ratio Is 1: 40 (1 part oil Always use the chain lubricating oll .approved by STIHL
to 40 parts regular gasoline) with STlHL two-cycle engine and appointed dealers.
oil or 1: 25 for other branded engine oils.
If special chain lubricating oil is not available, one of the
Important: Always shake mixture In fuel can vigorously high-duty, Single grade engine oils listed below may be
before fueling. - used In an emergency, d~nding on the outside tempe-
rature.

Outside temperature + 1O'C ... +40"C: SAE 30

Outside temperature + 10'C ... -10·C: SAE 20
Outside temperature -10·C ... --30OC: SAE 20 W or
SAE 10 W

Always top up with chain 011 when you refuel. Carefully

clean the area around the filler caps before opening and
make sure that no dirt falls inlo the tank while you are
22 refueling.

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 Helpers Handle
Top: TIghtening the clamp nut
Center: Mounting hardware fitted on bumper spike
Knocking out blanking plug Bottom: Guard rail in posttion

___ 6

'-'-_ _ _ _ 1
,--------~~~-~

For safety reasons and to Improve cutting accuracy ~ is

. . advisable to use the helpers handle (1109 660 2500) nyour
saw is equipped with a 105 em (42 In) or longer cutting
attachment. With the handle fitted a second man can safely
assist the saw operator in handling the saw.

When the helpers handle Is being used the non-cutting

side of the saw chain must always be covered by a guard
rail which matches the bar length.

To assemblethe helpers handle, first knockoutthe blanking

plug (3) In the slot (1) at the bar nose (2). Then tum the
clamp nut (5) (star knob) counterclockwise to rotate the
head of the clamp bott (4) so that it fits through the slot (1)
in the bar. The head of the clamp bon (4) is turned through
90" when the clamp nut (5) (star knob) Is tightened and
thus secures the helpers handle (6) against the guide
bar (2).

To attach the guard rail (7), first ffl the mountfng hardware
to the CI8J1kcase and the helpers handle and then place the
guard rail In posiIJon . 23

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 Starting
Top: Choke lever In " Choke" position (cold start)
Center: Choke lever away from" Choke " position (warm start)
Stop switcl1 away from "STOP " Bottom: Starting throttle position

"

To start the engine, place Ihe chain saw on the ground,

make sure you have a finn foothold and the saw chain is
clear of all obstacles and the ground. Bystanders must be
kepI well clear of the general work area of the saw.

Starting procedure

1. Move stop switch (1) away from " STOP".

2. If the engine is cold, move choke lever (2) to "Choke ".

If the engine is wann or has only been stopped for a
brief period, move choke lever (2) away from" Choke".

3. Set throttle trigger (3) 10 starting throt1le position by.

pressing the safety throWe lock (4), throttle trigger (3)
and starting throttle lock (5) In thai order. Le\go ofthrotUe
trigger (3) first and then the starting throtUe lock (5).

If you have an O9OAVfirsI squeeze the throttle trigger (3)

and press In the starting throtUe lock (5). LeI goofthrotUe
24 trigger (3) first and then the starting throtUe lock (5).

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 Top: 51.rting
Center: Idle position
Pressing the decompression valve Bottom: S10p switch In "STOP" position

*"__ 8

4. Hold the saw firmly on the ground with your left hand
around the handlebar (6) and put the toe of your right
foot into the rear handle and press down.

5. Press the decompression valve (7) with the th umb of

your left hand . Pull the starter grip (8) slowly with your
right hand until you feel the starter engage and then
give ~ a brisk strong pull.

The starter rope should not be pulled out more than

70 em (27 in) as there is otherwise a risk of it breaking .

Do not allow starter grip (8) to snap back. Guide it back

vertically so that the starter rope can rewind correctly.

6. As soon as the engine is running, release the decom-

pression valve (7) and immediately disengage the start-
ing throttle lock (5) by briefly squeezing the throttle
trigger so that the engine can settle down to idle speed.
• ,

7. To stop the engine, flick the stop switch (2) to the

"STOP" position. 25

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 ; other points to beobserved:~~·l~..,~ engine:
The choke lever:is mectianl~" &)ritJi~< the.·~­
retor's choke valve. The :dlOki:V8(Vltis the Closi,cfWhen
choke lever is 00 .. chOke t"skfWiiQ'n the ,CilOke lever is
moveda~ay, from .~ ~;~:~, ~;::~~:,;,·', Yi~:,:;:,~~".:~:, :.::~1} : ~ ;.,
- "' . I

I,' ~en 'Starti~ a-cold fihglne on~~p ~~'~~:~ve~ in

the " Choke poSition until the engine ~bj$~ :ftie. Then
II

open choke fully - chOICe rever'away·~tCfWk8" - ev,en

if the ,engine stops and you have ·to,·repeat:,thestartfng
prcx:edur~l.the choke lever ~.~iJl#:l~··.~·~ pqsition.
. the combustion chamber wllfftOQd8hd'_II'''~ri8/
.~~ .~'::: :·tt:~;~;·"; ~::,:.:51>'··: ·· :~ ;: ~( ~
If you moved tile choke lever 8Wlly!·frOJtli]hj ~~QiQke ..
position after ~~j~Qgtnefired B!td~"~a~~~((:~·~ot
run after sevEDI'"
.~ ~t
_t"
,o
His:alMQAU' ~ :In~SUCb a
. -·'~"'~ ' .':~ '-'1":~~:-'. ·' · ,,;,"' ~'· ""
.. " . : ••

: C8$~. re_'~,1ty9fUh!'~P!qg~~~~~s­
tionch~bY)~~gtht..~;~~~~~~n
. the starter:WiIti:the " ric'". "StiU'remoYed '8rid:,1Iuf"8lO
,
~~11ii",·':~~;~~;sTbpT~~~.
mOv8 :~'~e lever
~!p,i;y~q~
" , ~,~:~
__ n "e ~froril uChQk~~~f-,
qlneJfi(cold,- and set the 'throttle triggerJp,:1I18SJ8rt1ng
:'; tt1roUle'po$ition.. " ' · :,~' /.: :

, :~,~~:: ~~;+t :~~:'I~ the"choke slightly after

. ~:g:,:mqv~~rt.Ocenterposition.Alloweng,.ne
" to wsnntyp'for:j 1)rlet:P8rfod,at haIt.;;tfli'ottIe. Then move
choke 1eY8t'8Wi-fioRj ~ChOke" and diSen ' the start-
(n9th~",.~.bck
" ' , :, '.:'> .~: . " ",, ' :->~.. .
', ~./i>r":-:".j:;. . . :
:~>.~':.~:

A,f)ew engin8::o.~·W_~ been run until ~~~~~k

is dry will not start fI!St~8fter fueling becauS"1hecar-
buretor's dlaphragm~pqtiJp only deDvers sufft~J~el
26 after the engine haS b88atUmed over,several timeS:, '"

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 Oil quantity control
Top: 1 = Adjusting screw
2 = Counter nut . Top: . Adjusting the oil quantity
Bottom: Loosening the counter nut Bottom: Countering

At the factory the chain oil supply of the oil pump is adjusted The adjusting screw for regulating the oil quantity is located
to the standard cutting lengths of 53 em (20.9 in.) bar for althe rear-wall of the 011 tank and is coumered with a hexa-
090, 090 AV, 90 em (35.4 In.) bar for 090 G. When using gonal nut. Hold adjusting screw wlth fork wrench SW 10
longer guide bars rt is possible to adjust the 011 quantity and loosen counter nut wrth second wrench . .
according to the bar length used by means of the provided
adjustmem screw.

When tuming the adjusting screw to the left - counter

clockwise - more 011 Is supplied and when tuming to the
Before readjusting the oil quanttty remove Mer cover and right less 011 is supplied. Tuming the adjusting screw '/3 of
fllter, flrst, however, close choke shutter (posrtion "0") so a tum corresponds approx. to the necessary change of oil
that no dirt can drop Imo the carburetor. supply which is needed for the next longer bar length. 27

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 Cutting Attachment
, OUlntet borings
2 Gente,ring borings

On Roliomatic guide bars the bearing 01 the nose sprocket

must also be lubricated at regulated intervals with the
appropriate grease gun. Lubricate at least once druly under
normal operating conditions. Only use a high grade grease
for refilling the grease gun. e.g. refill lUbe 0781120 1111.

To lubricate, place chain saw on its side so that the bar

nose is firmly supported. Clean the grease hole and pump
in grease while slowly pulling saw chain around bar
(sprocket rotates) so thai bearing is uniformly filled. When
grease emerges at the hole on the other sid!> of the bar or
The cutting attachment of a chain saw consists of the guide around !be nose. sprocket, repeat the procedure on the
bar; saw chain and chain sprocket other side.

GuJdebar The sprocket nose bearing should be greased more often ff

the cutting attachment is used in damp conditions, e.g.
The nose and underside of the guide bar are subject to a working in snow. AfII!r finishing cutting work the sprocket
particularly high rate of wear. To avoid one-sided wear, tum nose should be .thoroughly greased from both sides to
the bar around every time you resharpen or replace the force moisture out of the bearing and prevent corrosion.
chain. Regular cleaning of the 011 Inlet holes and guide bar
groove is also important. The bar can be examined for signs
of wear at the same time.
Chain lubrication

A minimum bar groove depth of 7 mm (0.28 in) must be Never operate the chain saw without proper chain lubrica-
maintained in order to prevent the drive Unks fouling the tion. Check operation of chain lubrication and level in 011
bottom of the groove (the heels of the culler and tie strap tank before starting work.
would no longer locate on the guide bar track).

Hold chain saw with mounted cutting attachment over a

This depth should be measured at the point where the bat light background. Take care, the Ollomatic chain must not
is stressed mOst, I. e. the bar noee or: D'..!romatic bars and touch the ground. i. e. keep H at least 20 em (8 in) clear of
the area where most of the cuttiilg is done on RoliomaUc the ground. Run the engine with haH-throttle position.
bars. The guide bar must be replaced .1f the minimum depth ff an increasing patch of oil can be seen, chain lubrication
28 can not be maintained. is operating correctly.

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 Checking chain lubrication Wom chain sprocket

Breaking In OHomatic chain When the chaln saw Is operated at extremely low outside
temperatures a correctfy cold-tensioned Ollorpatic chain
Every new chain has to be broken In for about 2 to 3 mInu- will begin to sag noticeabl)i"as Hwarms up to noimal operat-
tes. Ample chain lubrication is essential during this period. ing temperature. The chaln must then be retensioned.
After breaking in, stop the engine, check chain tension and However, the chain must be slackened off again immedia-
adjust if necessary. tely after shutting down the saw. This Is necessary to avoid
contraction stress which would occur as the chain cools
down to ambient temperature.

Correct chain tension

The Ollomatic chain must always be slackened off after A new chain must be retensloned more frequently than a
finishing cutting work A chain properly tensioned when used one util h has stretched fully.
~ is warm would, when the temperature drops, be subjected
to such great contnaction stresses that ~ would break and
also damage the crankshaft and bearings.
Chain sprocket

The stress and strain on the chain sprocket are particularly

The Oilomatic chain must, therefore, always be tensioned- high. ~ the wear mar1<s on the teeth are very pronounced
w~ the engine switched off - before you start cutting. (about 0.5 mm/O.D2 In deep), the sprocket should be re-
Chain tension is correct In the cold condition when the pl8ced. A wom sprocket reduces the service life of the saw
chain fits snugly on the underside of the bar and can still chain. The chain sprocket should be replaced as a matter
be moved along the bar by hand. Extreme care must be n
of routine whh every secOnd Oilomatic chain. Is best to
!eken as ·the cutting edges are very sharp. use two chains alternately w~ one sprocket. 29

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 Air Filter
, = Oil filler cap
2 = Manual oiler
3 = Oil inspection window Disassembty of air filter

Alte r adjusting hold adjusting screw with a fork wrench The air filter's function is to intercept dust and dirt in the
and counter hexagonal nut again with second wrench. combustion air and thus reduce wear on engine compo-
Thereafter assemble air finer and filter cover again. nents.

Clogged air Mers reduce engine power, increase fuel

In extreme cases (failure of automatic oil pump, heavy consumption and make starting more difficun.
frost etc.) the use of the hand oiler assures sufficient chain
lubrication. The airfilter must be cleaned dally-or morefrequently
in very dusty operating conditions.

Also during longer cutting periods with longer cutting Before removing the finer, close the choke vaive so that no
lengths the chain is additionally supplied with lubricating dirt can get Into the carburetor. Unscrew the finer cover
all by activating the manual oller. Moreover, before starting and take out the filter element.
we recommend to supply add~lonal lubricating oil to bar
and chain by activating the manuai olier should the saw s~ For daily cleaning it is sufficient to clean the filter with a
idle at freezing temperatures for a longer period. Thus the soft brush. However, the complete' air fitter should be
cutting attachment is protected against excessive wear. washed In clean gasoline at least once a week and blown
out with compressed air IT possible (Hocked air filters must
not be cleaned with compressed air, brushes or rags).
The oil level can be -checked at the inspection window (3).
If the wire mesh is damaged on either hart of the air finer
(or If the fiocking is damaged), always fit a new part.
Always fill up with chain oil before starting work. Check
the oil level at frequent intervals during cutting and top ~ It is advisable to carry a spare filter with you at ali Umes
30 up before it drops too low. and clean the dirty finer in the workshop.

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 Carburetor
1 ~ High speed adjustment screw
2 ~ Low speed adjustment SCf9W

Notes for fine adjustment of carburetor

Engine stops while Idling:

Tum idle speed adjustment screw slightly clockwise while

the engine Is running (chain must not tum).

Chain turns while engine Is Idling:

Tum idle speed adjustment screw slightly counter-clock-

The cartluretor Is adjusted at the factory foy maximum wise.
performance and most econOmic fuel consumption under
average local atmospheric conditions. When working at
high altitudes (mountains) or near sea level the carburetor Engine runs erratically at Idle speed:
may need to be readjusted. This must be done with two
aQjustment screws and the Idle speed regulating screw. Adjust at low speed adjustment screw. Tum clockwise for
leaner mixture or counter-clockwise for richer mixture.

Basic adjustment of the carburetor.

Gautlon: The setting of the high-speed adjustment screw

High speed adjustment screw (H): short, affects the engine's maximum off-load speed, ~ ~ Is set too
1 tum open lean (adjustment screw turned too far clockwise), the maxi-
mum permissible engine speed of 6000 r.p.m. will be
Low speed adjustment screw (L): long, exceeded. This can resu~ in engine damage brought about
1 tum open by insufficient lubrication In particular.

Apart from minor readjustments, you should not attempt

Take this basic adjustment as a guide when readjusting carburetor adjustments or repairs yourself. Entrust such
your carburetor. Check carburetor adjustment with warm work to STIHL Service. In most areas you will find STIHL
engine and a clean air filter. Carefully screw In both adJust- Service Shops w~h trained specialists and the tools neces-
me.nt screw until snug litl sary for expert servicing. 31

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 Replacing the chain sprocket
Top: Inserted locking saew
Center. Loosening the crankshaft nut (090/090 AV)
Bottom: Sequence of component parts (090/090 AV)

Remove chain sprocket cover and cutting attachment.

Loosen and remove spari< plug with combination wrench.
Screw locking screw from your tool set Into cylinder and
tum crankshaft clockwise until the piston rests against the
locking screw thus locking the crankshaft.

On 090/090 AV proceed as follows:

Loosen hexagonal nut with combination wrench.

Attentionl The hexagonal nut is of lell hand thread-

loosen clockwise!

Remove front washer, spacer ring, clutch, spiet-sleeve,

rear washer, chain sprocket and needle cage.

Clean needle cage in clean gasoline and grease with

roller bearing grease.

When replacing the chaln sprocket assembling is done in

reverse sequence. Thereby care has to be taken that the
rear washer with the arched Indent at Its outer diameter
is pointing towards the crankcase.
•• - "
Tighten hex. nut with torque wrench at a torque ot 5.0 kpm
(36.2 Ibf. ft.).

On the 090 G the chain sprocket is held In place with pipe

plier; and the crankshaft nut is loosened by turning left:-
anticiockwlse. Remove washer underneath the nut and
pull off chain sprocket by means of special puller
32 1109 890 4401.

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 Gear lubricant 090 G
Top: loosening Ill. hex. nut (090 G) Opened gear COV9(
Bonom: Pulling off the chain sprocl<et (090 G) 1 = Filler screw for gear lubricant

The spur gear of the 090 G Is lubricated by a motor all of

group HD SAE 30. To avoid a maitunction of the centrtfugal
clutch this all brand must be used under all circumstances
for new fillings and when refilling .

The oil level in the gear should be checked weekly. At hori-

zontal position of the machine the all level should be at the
lower edge of the tap hole of the lOCking screw. ~ not, the
respective quantity 01 all must be refilled.

Clean and grease shaft end. Heat new chain sprocket

sL!fficlently and slide. ~ onto thedrMng shaft; thereby At least every 6 months the all In the gear must be renewed .
taking care that the key groove Is guided properly over the Put machine with gear cover pointing up, screw outmanuai
key. Then place washer and nut onto the shaft, countemold oiler and remove gear cover. Empty the old oil and pry oft
chain sprocket with pliers and strongly tighten hex. nut. cap on clutch drum by means of a screw drIVer. clean gear
and clutch thereafter ~ clean gasoline.

Press cap tightly onto the clutch drum again, put on gear
Remount cutting attachment and chain sprocket cover. cover and tighten. Th,en screw in manual oiler. Remove
Remove locking screw and mount spark plug again. locking screw and fill In 0,151 (0.32 pt.) all. 33

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 Rewind starter
Top: Prying oft the ret:alnerwasher
loosening the fastening screws Bot\om: Component parts

Rer>laclng a broken ataf1er rope:

Unscrew the 4 screws holding the fan cover and remove

fan cover. On 090 G, however, first remove handle tube
support. Pry off the retainer washer from starter shaft with
a screw driver thereby holding brake washer in place in
orner to avoid that ~ Jumps out thereby loosing the brake
spring.

Now the component parts of the rewind starter can be

removed.

Be careful when removing the rope pulley. The hooked in

rewind sprtng must not jump out. Remove the remaining
piece of the old starter rope, thread in anew rope of 4.5 mm
(Q.18 In.) !1l .and 1000 mm (39.4 In.) length and secure In
the pulley with a single knot Thread the other end of the
rope through the rope bushing In the fan cover and secure
it in the starter grip with a double knot Don't wind up the
rope.

Mount rope pulley onto the starter shaft thereby applying

some oil and take care that the cast lug of the rope pulley
34 Is hooked properly Into the loop of the rewind spring.

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 Installed rewind spring Tensioning of rewind spring

Now reinstall the remaining parts of the rewind starter in Tensioning 01 rewind spring
. - the correct sequence as shown on the illustration.
Hold the uncoiled rope close to the pulley and Insert the
It is important that the two fiber material washers have to rope ·into the notch at the periphery of the rope pulley.
be inserted in front of and behind the friction shoe system_ Now tum rope pulley by means of the rope 4-5 turns In
The friction shoe system is mounted property when the clockwise direction - to the right - thereby tensioning the
lugs at the spring retainers point In clockwise direction. rewind spring. Hold rope pulley, rearrange twisted rope
Secure rope. with retaining washer and tension rewind and pull out completely.
spring.

Release rope pulley and slowly let starter rope go so that

it colis itsen automatically onto the rope pulley by the
Replacing a broken rewind spring attained pretenSion.

The spare spring Is supplied ready lor Installation complete The rewind spring is properly tensioned ij the starter grip
with spring housing and should be applied with a few drops Is tightly pulled into rope bushing and does not tin sideways.
of oil belore mounting. At fully pulled out starter rope one should sti.ll be able to
tum the pulley at least ';' tum until maximum spring
Insert recoil spring wHh spring housing - housing bottom tension Is reached. Otherwise pull out starter rope, hold
pointing downwards - in the Ian housing and hook outer pulley and uncoil rope by·one layer. Then remount Ian cover
spring lug into the cast lug 01 the fan housing. Should the and on 090 G handle tube support.
rewind spring jump out during Installation loop it back into
the spring housing in clockwise direction starting with the
outer loop and ending wHh the inner loop. Cover rewind Excessive spring tension will cause breakage 01 the
spring with washer and mount rope pulley again. spring. 35

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 Maintenance Chart

i~ i
I:II&,
i aCi 1.r I Ii iii

jf Jt!cai f
.it- 1:11
:5 ~ !
... "iii
1»3
=ale i S
:::
i
:::
0'.1
CD
G)

I
Visual inspectlon (condition, leaks) x x
Complete machina
clean x
Throttle !Jigger, safety tt'llvttSe lock. stop switch.
Master Control, dep8ncfing on model Check operation x x
Check operation
ChaIn brake Clean
Clean wire fifter x
Filter In fuel tank x
FI8pIace felt
Fuel tank Clean - x
Chain oil tank Clean ·x
Chain lubrtcatlon Check x 28,29
Inspect, also check sharpness x x
Saw chain QIe.CI( chaln tension x x 29
Sharpen x 39
Inspect (wear, damage) x 28
Clean and tum aver x x
-_.
Guide bar
.
~

Deburr x
Replace x x
ChaIn sprocket Check x 29
Clean x 30
Alrfilter x
Replace 30
Cooling InIe1s Clean x
Cylinder fins Clean x
Check Idle adjustment-
Carburetor chain must not tum x x 3t
Readjust Idle x 3t
Spark plug Readjust eleCtrode gap x
~accessible SCI'8W8 and nuts
adjusting screws) Retighten x
Inspect x
Rubber vibration buffers To be replaced onlY by STlHL Dealer x
Inspect. depending on model
Spark'arrestor screen
Clean or replace
Check x
Chain catching bolt
36 Replace x

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 Specifications 090, 090 AV Specifications 090 G

Engine
STfHL single cylinder two-stroke engine
Displacement: 137 ems (8.36 cu. in) 106 cms (6.36 eu. in)
Bore: 66 mm (2.6 in) 58 mm (2.3 in)
Stroke: 40 mm (1.57 in) 40 mm (1.57 in)

Ignition System
Type: Flywheel magneto Flywheel magneto
Ignition timing: 2.9-3.1 mm (0.114-0.122 in) before T. D.C. 2.9-3.1 (0.114-0.122 in) beforeT.D.C.
Breaker point gap: 0.35-0.45 mm (0.013-0.018 in) 0.35-0.45 mm (0.013-0.018 In)
Spark plug: BoschWSR6F BoschWSR6F
Champion RCJ 6 Y Champion RCJ 6 Y

Fuel System
. - All position diaphragm carburetor All position diaphragm carburetor
Fuel capacity: 1.2 I (2.5 US pt) 1.21 (2.5 US pt)
Air filter: Flocked wire mesh element Flocked wire mesh element
. Fuel mixture: Mix ratio 1: 25 with SAE 30 Mix ratio 1: 25 with SAE 30
two..cycle engine oil; 1: 40 with two-cycle engine oil; 1: 40 with
STlHL two-cycle engine oil STlHL two..cycle engine oil

Cutting Attachment
Bar lengths: 53, 63, 75, 90, 105, 120, 150 cm 90, 105, 120, 150 em
(20, 25, 30,35,41,47, 59 in) (35, 41, 47, 59 in) ,
use helpers handle on guide bars of 105 em use helpers handle on guide bars of 105 em
(41 in) and longer (41 In) and longer
Chain: 0.404" (10.26 mm) and 112" 112" (12.7 mm) pitch
(12.7 mm) pitch
Chain sprocket 6 and 7-tooth 6-tooth
Chain lubrication: Fully automatic with oil feed control and Fully automatic with oil feed control and
supplementary, unit-mounted hand pump supplementary, unit-mounted hand pump
Oil capacity: 0.53 I (1.1 US pt) 0.531 (1.1 US pt)

Weights Gearbox
Type: Spur gear
090 with 53 em (21 In) bar and chain: approx. 13.9 kg (30.6Ib) Reduction ratio: 2: 1
090 AV with 53 em (21 in) bar and chain:·approx. 14.6 kg (32.2 [b) Lubrication: HD SAE 30 engine oil
090 G with 90 em (35 In) bar and chain: approx. ',68kg (37.1 Ib) 011 capacity: 0.151 (0.32 US pt) 37

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 Ordering Spare Parts

For ordering spare parts fill in below the model name of

your power tool, the machine number as well as the part
number of your chain and guide bar. .

This makes ordering of a new chain and bar easier as

both parts are wearing parts. The part number for the
chain sprocket which from time to time must be replaced
as well is already filled in; also the part numbers for the
standard chain and guide bar are already filled in.

When purchasing these parts it is sufficient to just men-

tion the model and the respective part nLimber.

The machine number is found at the crankcase, the part

number for the chain is marked on the chain box and the
one of the guide bar can be found on the guide bar
packaging.

Model description I I I I I I I I I I I I 1.1

Serial number o rn [IT] [IT]
Chain part number IIIII [IT] IIIII
Guide bar part number IIIII [IT] IIIII
Sprocket part number IIIII [IT] IIIII

Chain sprocket 0.404" (10,26 mm) 7T 1106 640 2015

Standard chain Rapld-Standard 3812 000 0072
Standard bar 53 em (21 In) 3001 000 9223

Guaranty for repairs can only be given if the repair

work is done by an authorized snHL-Service' Shop
38 using original snHL spare parts.

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 Sharpening and Maintenance
of Saw Chain
Top: Component parts of an Oilomatic chain
Bottom: Measuring chain pitch "tft .

Description of chains

The illustration on the right shows the component parts of

a STlHL saw chain. Every chain manufactured by STIHL
features the OiJomatlc system. Apart from the three basic
types (Rapid, Topic and Picco), there are three different
versions whose names denote the cutter shape, i. e. chip-
per tooth ~ Standard, semi-chisel ~ Micro and full chisel ~
Super.

The main size measurement on a saw chain Is the prtch. It

is detemnined by measuring the distance between one ri-
vet and the next but one and dividlng'the measurement by
two. The resutt is the pitch which is generally specified in
" inch ("Ar ~ 9.32 mm).

Like any other cutting tool, the saw chain is subjeclto nor-
mal wear and tear. A properly sharpened chain slices
through wood and requires very little infeed effort, For this
reason alone you should never attemplto cut with a dull or
damaged chain. There are a few crucial angles which must
be observed in order to obtain good resutts when sharpe-
ning a chain. They are explained below.

Filing angle

The filing angle for Rapid-Standard, Rapid-Micro and To-

pic-Micro chains is 35'; these chains are sharpened to this
angle before leaving \he factcry. However, ij you want to
use the chain primarily for cutting hardwood or frozen tim-
ber, it is best to sharpen it to an angle of 3~'. Rapid-Super
and Topic-Super chains are always sharpened to 3~'.

tt Is essential to ensure that the filing angle is kept exactly

the sarne on all cutters. Irregular angles will cause the
t·t
chain to run roughly and unevenly as well as accelerate
the rate of wear and increase the risk of breakage. 39

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 Top: RUng angle
Center: Side plate angle
Bottom: 1hbIe of file ~ers

'. ' . " " , .~. -';'.<,.: :··:::r<~~<:~ ':: Side plate angle
~" ~ .'. '~.\.

The upright cutting edge just below the top plate is known
as the side ' Plate cutting edge. ' The side, plate angl~ is,
therefore, the angle between the side plate cutting edge
and the horizontal·line formed by the cutter toe and heel.
The following side plate angles are specifiEl9:

Rapid-standard Topic-Micro
Rapid-Micro Topic-Super
Raptd-Super

These angles ' are obtained automatically if you use a file

holder or roller flUng guide withthespectfied size of tile
(diameter) and hold the file correctly during sharpening.

Top plate cutting angle

The top ~ate cutting angle is the .rnost important angle

since it influences the chafn'scutting behavior•. It is also
obtained .automatically if sharpening is performed pr0-
perly with a suitable STlHL sharpening tool.

Sharpening

OnlyspeciaJ saw chain flies may be used for sharpening

Chain pitch ' Filedia. RleNo. and they must match the chain concerned ·(basic .type,
pitch). The shape and cut of machinists' flies makes them
' .325" (8.25mm) Ra,:rid'~.r (4.8mm)·08,141, 80ss unsuitable for saw chain. It is best to use the speciaJ chain
. ' ~25" (8.25·mm) Topic %f(4~o.,mmFO)1,4 242 ~ fllewith :aflle holder or other flUng-aid. Always file from
. W .. (9.32mm)·RaPid¥ltf(4~8mm)Q8114118088 the inside to the outside of the CIdIer. If yoU sharpen the
W (9.32 mm) Topic ~ (4.0 mm) 0814 242 ~ chain while It Is on the bar, increase chain tension before
.404" (10~ n'lm) ~tf (4.8 mm) 0811 411 8088 filing and reset It to correct tension afterward.
W (12.7r.nin) tAli (6.3mm) 0811411 811~
All cutters must be filed to the same length. Since the top
40 plate slopes downward to the rear (clearance angle), the

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 Top: RI. position for Rapld-slandard, Rapid-Micro and
Topic~M i cro
Bottom: Sh""",ning with file holder File position tor Aapid-5uper and Toplc·Super

.. ,. - to'
i

Micro and Topic-Micro chain so that ~ is at 90' to the

perpendicular faces of the chaln 'Iinks or the guide bar,

On Rapid-Super and Topic-Super chains the file must be

gulded' so that the handle Is 10' lower than the tip of the
file, i. e. In this case the file must run upward at an angle of
10' to the horizontal. A filing aid (file holder, filing too~ must
always be used for sharpening Rapid-Super and Toplc-Su-
per chains.

File evenly and steadily and note that the file only shar-
pens on the forward stroke- Uft the file off the cutter on
the backstroke. Make sure you do not touch the tie straps
cutter heights will be uneven ~ the cutter lengths are diffe- and drive links with the file. Use a piece of hardwood to re-
rent. If the cutters are not all the same height the chaln will move bunrs from the cutting edge.
run roughly and eventually break.
I's ~ is very Important to.achieve unijonm cutler lengths, ~ Importam: Sharpen the chain frequemly and take away
is best to measure them with a slide caliper. Find and shar- as little material as possible. Two or'three strokes of the file
pen the shortest cutter first and then use ~ as a master for are usually suffciem to the keep the chain sharp. varia-
all the others, J. e. all cutlers must be filed back to the tions In angles and the lengths of the cutlers cannot be
same length as the mester cutler. Sharpen all the cutters completely avoided during manual sharpening. For this
on one side of the chaln first and then repeat the proce- reason the chaln should be restored to ~ Original condi-
dure on the other side. tion with a workshop chain sharpener (STIHL USG, SnHL
FG 2)' after rt has been resharpened about five times by
The file must be held level for Rapld-standard, Rapid- hand. 41

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 Top: Table of recommended depth gauge settings
Center: Depth gauge setting
Bottom : Filing down depth gauge (Topic chain)

Depth gauges
Chain pitch Setting Filing gauge
The depth gauge determines the height at wh ich the cutter
enters the wood and thus the thickness of the chip remo- .325" (8.25 mm) 0.65mm . 1110 893 4000
ved. The cutting capacity and life of a saw chain are there-
W (9.32 mm) O.65mm 11108934000
fore influenced by the distance between the depth gauge
and the cutting edge, i. e. the depth gauge setting. This .404" (10.26 mm) O.8mm 1106 893 4000
setting varies according to chain p~ch and must be chec- W (12.7 mm) O.Bmm 1106 893 4000
ked with the appropriate filing gauge. 090 G chain saw
W (12.7 mm) 1.2 mm 1106 B93 4010
The best cutting resu~ are obtained with the settings li-
sted in the table. However, the depth gauge setting may
be increased by 0.2 mm for cutting scftwood in mild weat-
her conditions.

Since the depth gauge setting is reduced when the cutter

is sharpened, its height must be checked and lowered if
necessary. If iIle depth gauge projects from the fil ing
gauge, itmust be·filed down level with the gauge using a
flat or triangular file. The contour of the depth gauge must
alsc be rounded off on Rapid chain. In the case of Topic
chains the depth gauge should be rounded off in line with
the stamped markings.

General chain maintenance

Chain maintenance begins as soon as the chain is fitted

on the bar and sprocket. The essential points are correct
chain tension and ample lubrication. See aisc "Guide
Bar, Chain and Sprocket".

Clean the chain thoroughly in gascline after sharpening to

42 remove filings or grinding dust. Then lubricate the chain by

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 Table of file holders

. immersing it In an oil bath. If you are not going to use the

chain for a prolonged period, clean it with a brush and Chain pitch Chain File holder
immerse it In an oil-paraffin bath. inch(mm) Part No.

Carefully examine chain for cracks in'the links or damaged .325 (8.25) Rapid~Micro • 5605 750 4326
rivets while you are sharpening and cfeanlng it. Any dama- .325 (8.25) RaPid-8uper 5605 750 4336'
ged or worn parts' must be replaced. The new parts must .325 (8.25) Topic-Micro 5605 750 4321
be reworked to match the shape and size of the original .325 (8.25) Topic-Super 5605 7504351
parts.
% (9.32) Rapid-siandard 56057504326'
Chain repairs can be carried out With the STIHL handheld
> % (9.32) Rapid-Micro 5605 750 4326
chain breaking and riv~ spinning tool, the STlHL NG 1 or % (9.32) Rapid-Super 5605 750 4336
NG 5 rivet spinners and the STIHL NG 4 chain breaker. % (9.32) Topic-Micro 5605 7504321
% (9.32) Topic-Super 5605 750 4351

.404 (10.26) Rapid-Standard 5605 750 4326

.404 (10.26) Rapid-Micro 5605 750 4326
.404 (10.26) Rapid-Super 5605 750 4336

Tools for chain maintenance

There is a range of chain sharpening aids and tools to suit

the users needs (frequency of sharpening, time required
etc.).

FIle holders, which have reference marks for the filing

angle, stmpllfy chain sharpening and are aval1ab1e for all ty-
pes of chain.

The FG 1 filing tool attaches to the guide bar and shar-

pens all types of chain.

The STlHL FG 2 Filerlte and USG universal electric

sharpener are workshop tools suitable for sharpening ail
types of chain. 43

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 6

1 .. 85° side plate angle 1 CI Sprocket pitch

2 1:1 70° side plate angle 2 .,. Chain pitch
3 ... aoo and 90° side plate angles 3 a Drive link gauge
4 35° filing angle (Standard und Micro)
Q 4 .,. Groovewidth
5 a 3Qofiling angle (Supelj 5 ... File diameter
6 a Depth gauge setting 6 III Lug for cleaning bar groove and
7 ... Groove cleaner and scale for cutter length oil inlet hole
and groove depth

The filing gauge is a universal tool for checking the filing The reference gauge 0000 893 4105 is used to detennine
and side plate angles as well as the depth gauge setting the distinguishing characteristics of saw ohains and guide
and outter length. It can also be used for oleaning the guide bars. Furthermore, it can be used to olean the guide bar
. bar groove and oil inlet hole and measuring the groove groove and oil inlet hole as well as oheck the diameter of the .
depth. The following fiUng gauges are available: ohain sharpening file.

Filing gauge 1110 893 4000 for 0.325" and %" ohain
(0,65 mm dep~ gauge setting).

Filing gauge 1106 893 4000 for 0.404" and '!h" chain
44 (0,8 mm depth gauge setting).

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