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8nHL 090, 090 AY, 090 G


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 service. To receive maximum performance and satisfaction from your STlHL chain saw, it is important that you read and understand the maintenance and safety precautions before using your saw. Contact your STlHL Dealer or the SllHL Distributor for your area if you do not understand any of the instructions or warnings in this Manual. This Manual contains warnings regarding your saw, operating and safety instructions for all STlHL 090 series power saws. Warning I

Because a chain saw is a high-speed wood-cutting tool, some special safety precautions must be observed as with any other power saw to reduce the risk of personal accidents. Careless or improper use may cause serious or even fatal injury. It is important that you fully understand 'the contents of this Manual and that you allow only persons who understand this Manual to operate your chain saw.

Contents Parts of the Chain Saw Satety Precautions - The Operator -The Saw - The Use of the Saw - Maintaining and Storing the Saw Mounting Guide Bar and Chain Fuel Chain Oil Helpers Handle Starting 011 Quantity Control Cutting Attachment Air Filter Carburetor . Replacing the Chain Sprocket Gear Lubricant 090 G Rewind Starter Maintenance Chart Specifications Sharpening and Maintenance of Saw Chain

2 4 4 6 6 19

20 22 22 23

24 27 28

30 31

32 33 34 36 37 39

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 products. 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 STlHL Dealer for updated information and assistance. 0458 166 0121. MO,7S.AO.1: Printed In West Germany


STIHL~ C 1990 Andreas Stlhl, Walblingen

Andreas Stihl D-7050 W8lblingen


Parts of the Chain Saw

4 Front hand

Guide bar nose


Guide bar


5 Front handle tenninal


of filter cover Bumper spike 13 Clutch l '


O'lain catcher 15

Oil hand



12 Oil

22 Chain


Choke lever 18

throttle lock 19 25 Slarter


throttle lock 20

14. ClUtch. C()upJes engine to chain sprocket when engine is accelerated beyond Idle speed.

Defil1llfOns 1. Oilo~ Saw Chain. A J09P ~ of cutters. tie straps ~drive links. . ',' ~,.-

2. Guide Bar. Su_~:ijuJdes the saw chain. . ";.,:


)"'~: ~:/r~

3. Gu. . ~rNose.:~~,paitoftheguidebar.


15. Chain Catcher. Catches a broken chain and guides It inside the chain sprocket COVet

~ ~auarii.-~.::\~ ~ .,." PI, agafnst Pro..

jecting ~fInd helps prevent the left hand from touchi ttcEt Ch8tn if It 'slips off the handle bar• , • 0< ,.:,._.,..J!~t ",,-of.. ' ' , ' , ,,,,, ,


cta8fr. 8prf;K=ket. The toothed wheel that drives the



17. Chain.Sprock8t Cover. Covers the clutch and the sproClCet. 18. Choke

Lever. Eases engine starting by



5. Front Handle. Handle bar for the left hand at front of


19. Startfng Throttle Lock. Keeps the throttle partualJy

6. Sp;idc Plug TemdnaL Connects the spark plug with 1he i9nHiOn


7. Lock'or-Filter Cover. For remoVing filter cover, per-

rnitS1Uter to.be cIearied.: 8. ,Rear'Handle-The Support handJe for the right hand, . Iocited at or tOward the rear of the saw.

9. Oil Fftier ~For closing the 011 tank.

11. Oil Hand Pump. For additional manual c::;haln lubrication..


level. 13. BUmper ~ Toothed stop for holding saw steady againSt wood.


~ Throttle

Look. Must be depressed before

~ the throttle trigger.

21. Throttle TrIgger. Controls the speed of the engine.

22. ChaIn Guard (Scabbard). Protects the operator from touchil1$1 the chain. 23. Decompfession Valve. Makes starting easier.

10. Stop Switch. Switches the engine's ignition system off and stops the running of the engine.

12. 011 Inspection WIiu:Iow. For contrO'mng the chain

~n ~ring starting.

24. Muffler. Attenuates exhaust noises and diverts exhaust gases i~, req~lreQ ~on. 25. Starter ~'The, grip Of the, pull ,starter. which is the device to start the engine.

26. Fuel FlUer Cap. For closing the fuel tank.


Safety Precautions


The use of any chain saw may be hazardous. The saw chain has large, sharp cutters. If the cutters contact your flesh, they will cut you, ewn H the is not m9VIns.' At full throttle, the chain speed can reach 45 mph '(20 ri1Is). It is important that you read, fully understand and observe the following .safetY precautions and .warningS. ;Read the owner's manual and the safety' inStructions periOdically. Pay special attention to the section on reactive forces, pages 10 to 13.



Warning! Reactive forces, including kickback, can be dangerous. Careless or improper use of any chain saw may cause serious or fatallnjuiy. . ' ,. All safety precautions that are generally observed when working with Bnaxeor a'hand saW aisoapply ~ the'opefalion of chain saws. HOWever; beCause '8 Chain saw is a hlghspeed, fast cutting power tool,~a1 safety precautions must be obSerVed to reduce ,tti~~ risk of personal accidents. .- . Have your ,STIHL dealer show you how to operate your chain saw. ObserVe all appllCabra'~ safetY 'regulations, standards and ordinances. ,Warning! Minors should never be allowed to use a chain saw.

Bystanders, espedally children and anim~s should .not be allowed in the area where a chain saw is in use (ill. 1). Never letlt\e saw run unattended. $.Ore it in a locked place away from 'Children and empty the fuel tank before stonng for longer than few days. . . Do not lend Y'0ur chain saw without the Owner's Manual. Be sure that 'anyone' 'using ,yO~'saw understands the information contained in this Manual. These safety precautions and waqlings apply to the use of all STlHL ~n saws. Different ~odc$ may have ~erent parts and controls. See the 'appropriate section of your Owner's Manual for a description of the controls and function of the' p8rts of your model



Safe use of a chain SaW involves t the operator 2. the saw 3. the uSe of the saw. THE OPERATOR Physical Condition You must be in good physical condition and mental health and not under the influence of any substance (drugs, alcohol), which might impair vision, dexterity or judgment.

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. 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 disease (Raynaud's phenomenon). This phenomenon reduces 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 antivibration 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 guarantee that you will not,sustain Whitefinger d"lS8ase~ Therefore continual and regular users'should 'monitor clOsely .their use of chain saws and their physical condition. Proper Clothing . '. CIOthil1Q 'musfbe stUrdy and snug-fitting. but allow c0mplete fieedom of' movement. AvOId Ioose-fitting jackets, ~ ~.jeweirY. ~ or~ pants, or anYthing 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.

Good footing is most Important in chain saw work. Wear sturdy boots with nonslip soles. Steel-toed safety boots recommended. . ," >. Proper eye protection Is a must. Non-fogging, vented goggles or a.face screen is recommended. Their use reduces the risk of eye injury. " " 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.



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 bar, ~v~red with the ch~n.guard., Properly ,secure your to prevent turnover, fuel SpHlage and damage to



the saW.




Prepaf8tion forihe use of the saw THE SAW

Parts of the chain saw; Illustrations and definitions of the parts see pages 2 and 31

~I NevermodHy a chain saw in any way. Only attachments supplied by STlHL or expressly appro~,!)y STlHL ,for use with the specific STlHL saw modelS ,are. authorized. Although certain unauthorized attachmentsaie useable with the STlHL powerhead. their use may, in fact, .be extremely dangerous. '

T~ off the chain guard and inspect for safety in operation. For please foUow ~ procedure described at


the appropriate section "Mounting the Bar and Chafn" of your owner's Manual. '

STlHb-Oilornatic chain, guide bar and sprocket must match

eaCh other:' ' " . ." If the, g~i48 ~r 'or chain Is ~1aC8dt it must be with a bar

or Ch8In of the same type. ReplaCement with another type of guide bar or chain 'wiD seriously increase the 00,ances ,of ope~ iF.ljury ~ue t() the Contact of the 'moving chain with .~ operator during n;rtational kicIcb8ck.


W8rnirig! TranSporting the chain saw W8ming!

AJW8yS Stop the enQtne before'pUtting a chain saw down or

carryi~ ~. ~ ~ .chain' sti~;with ~' engine running is extteinely dangerous. 'A'CCidentaJ acceleration of the engine eancsuse the chain to rotate. Avoid touchmg the hotmUffter.' . .~ .


By hand: When carrying your


by hand, the 'engine

Proper tension of the chain is extremely important. In order to av~ ~ .setting the tensiol1ing ~we must 'be fot~ as, d~ in Y9ur ~"'M~,~ys ~re ~h,e*agoraarn~s>'fotthesp~coveriS(~)~ seCuteJy after tensioning, ~e .chaffL CheCk Chain t~n

after t:taving. tigtlte.ned the n~ and thereafter at regular intervals (Whenever the saw is shut off). If the


chain becomes loose while cutting, shut off the engine and then tighten. Never try to tighten the chain while the engine is runningl

5 Fueling

- Your STlHL chain saw uses an oll-gasoline mixture for fuel (see chapter" Fuel n of your Owner's Manual). Warning! Gasoline is an extremely flammable fuel. Use extreme caution when handling gasoline or fuel mix. Do not smoke or bring any fire or flame near the fuel (ill. 5).


Starting Wamlng!

Your chain saw is a one-person saw. Do not allow other persons to be near the chain saw. Start and operate your saw without assistance. . For safe and specific starting Instructions. see the appropriate section of the Owner's Manual.

Fueling Instructions

Fuel your Chain saw in well-ventilated areas, outdoors only. Always shut off the engine and allow It to cool before refueling. Relieve fuel tank pressure by loosening fuel cap slowly. Select bare ground for fueling and move at least 10 feet (3 m) from fueling spot before starting the ~ngine. Wipe off any spilled fuel before starting your saw and check for leakage. Check for fuel leakage while refueling and during operation. If fuel or 011 leakage is found, do not start or run the engine until leak is fixed and spilled fuel has been wiped away.

Do not drop start. This method is very dangerous because YC?':I maY.lose control of the saw (ill. 6). Place the chain saw on finn ground or other solid surface in an open area. Maintain a good balance and secure footing. Be absolutely sure that guide bar and chain are clear of you and all other obstructions and objects, including the ground: because when the engine starts at startingthrottl~, engine speed will be fast enough fOr the clutch to engage sprocket and tum the chain, which may cause kickback to occur.

Engage the chain brake when starting a QuiclCstop model. (see chapter "Chain Brake" in your Owner's Manual).


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. For directions to adjust idle speed, see the appropriate section of this Owner's Manual. Do not use a saw with incorrect idle speed adjustment. Adjust the idle speed your..self according. to the' appropriate section of this manual.

Warning,! Avoid stumbling on obstacles such as stumps, roots or rocks and watCh out for holes or ditches. Be extremely cautious when working on slopes or uneven ground. There is increased danger of slipping on freshly debarked logs. . Cutting Instructions

Have your STIHL Dealer check your saw and make proper adjustments or repairs. . After adjusting a chain start the saw, letthe engine run for a while, then switch engine off and recheck chain tension. Proper chain tension Is very important at all times. Working COl\dltlons

Operate your chain saw only outdoors in aventilated area. Operate the saw under good visibility and daylight conditionsonly.


Warning! Take extreme care in wet and freezing weather (rain, snow, ice). Put off the work when the weather is .windy, stormy or rainfall is heavy. Clear the area where you are working.

Grip: Always hold the saw firmly with both hands when .. the engine is running. Place your left hand on front handle bar and your right hand on rear ,handle and throttle trigger.. Left-handers should follow this instruction too. Wrap your fingers tightly around the handles, keeping the handles cradled between your thumb and forefinger (ill. 7), With your hands in this position, you can best oppose and absorb the push, pull and kickback forces of your saw without having it slip out of your grip (see section of reactive forces). Make sure your chain saw handles and grip are in good condition and free of moisture, pitch, oil or grease. Wamlngl'Never use the saw with one hand. You cannot control reactive forces (see pages 10 to 13) and may lose control of the saw.

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.·


Reactive forces during the cut, including kickba-*

WARNING! Reactive forces, that may occur during any cut are kickback, 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 difficult it becomes for the operator to controf the saw.


..- ~


Many factors influence the occurence and force of the !kickback reaction. The ~ of bar and saw chain you ~ ~ is a factor in the force of ttie-klCkback reaction. ;The speed of ~ ~wh" the cutter contacts the object. .,' _ ~" <.~,

),' -'_'. ". -

,Kickoaclfforces'Inereuewlth the raleOf Impact· il ',' >






~_ct~~ u.; ~ose of the b,ar and the


': ,.:



KickbaCltVmosfproriOunc:ed '"1M upper quadrant of the ~bar ROSa,


SOme STlHL chain types are designed to reduce kickback forces.

The.cJeptb.aauges:' Improper lowering of the depth gauges also Incre~ the chanceofa~ :1

The sharpening condition: warning! Adun orimproperty sharpen.ed ~ may Increase the risk of kickback. Always cut with a property sharpened chain.

operatOr's left hand is gripping the froI1t hBrldle behind the hand guard, and if the left hand rotates around the front handle and contacts the front: hanef guard, which is the ,Quickstop activating lever,. this contact will activate the . Quickslop and,~ the;chaln'(~ ill 13). '

\The ~.brake of some STlHL chain saws is additional . self-activated by fnertia.· see appropriate. ct1apler "ChaIn Brake"dt yo~r
STlHL taas~ d~~ chains whoseconftgu,r~ are ~ned.to reduce.~ forces. These. chains are available as an option.


Warning! Chain saw kickback may cause serious or fatal 'injury. To reduce the risk of kickback injuries snHL'recommends that you equip your anarrow),ose bal, lOW profile chain or oth8r chatn deSIgned to reduce 'kickback forces,


.. ~aS11HL~. ",

Devices for reducing the risk of Idckback Injury STlHL has developed a chain stopping system to reduce the risk of injury In certain kickback sItuations.Jt ~ called a Quickstop. ., The, ,Quickstopis, av-.i~ as an optiQn on most STIHL chain.saws. ' . ""

Wti. a~ oc:curs

the guide.bar may iotate around the front handle. H the cutting position Is such that the

Warning I ~o Qulcksk;Jp or

ch~ ~ de~ .prev&n!SkIckback. These devices are designed only to stop the chain. if activated, in.certain kickback situations.

In ~r for the Quickstep to reduce the riSk of 'kiCkback inj~, it mUst be P"'~ mai~ anei'ln gOod working order. In addition, there must be enough distance between the bar and the operator to ensure that the Quickstop has sufficient time to activate and stop the chain before potential contact with the operator. '


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 guarantee'th8t'you '!III not be Injuied by kfcftback,~and therefore always- observe aU safety prec8utlons to avoldldckback situations. To avoid kickback

8. Use extreme caution when re-entering a-previous cut. ,

• >


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

The best' protection -from perSonal injury that may result kickback· Is to avoid I
10. Be alert for shifting of the log or other forces that may cause the cutto close arid pinch the chain.

1. ~kI the chain saw firmly with both hands andlnalntain a secure grip.

11. Maintain saw chain properly. Cut with a correctly sharpened, 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.






3. Never bring the nose Of the guide bar In COntactwfth any . ~bject. Do not cut limbs with the nose of the guide bar. . Be'~DIhi ~.'.1 car8fulWhti .smalftb' . ug h'nmbS.

sman SIze

, brustf antf'saplIngs which may eaSily. catch the chain. . ." ~.-


4. Don't overi8ach.


7. Cut only one log at a time.



5. Don't cut above shoulder height.

Pusliback: ~hback occurs when the chain on the top of the bar is suddenly stopped when Ills pInChed. caughforencounters a foreign object in . . wood. The reaction of the chain drives the saw straight back toward the operator causing loss of saw cOntrol. PUshback frequenttyoccws when the top of the bar Is used for cutting (see 111.14).

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.


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. 2.

rlc? notcut~reth~ one log at a time. ' ,

3. Do not twist the • when withdrawing the bar from a plupge cut or und8r~ cut (figures 25 to 'Zl and 33, pageS 16, 17 and 19),' becaUse the chain can pinch.



Pull-ln: PuU-ln occurs when the chain ,on the bottom of the bar Is suddenly stopped. The,chain on~8 bottom oUhe bar stops when it is pinched, caught or encounters a foreign object In the wood (see HI. 15). The reaction of the chain pulls the S(lW forward, causing Ute operator to Iotle control. Pull-4n.frequently occurs when the buR.per sPIke of the saw Isnot.I)eId,secureIy against the tree or limb and when the chain is not'rotating atJuU speed before It contacts the wood.

Femng is, cuttll'I9 down a tree. Before femng a tree, consider carefully afl conditions which may affect the direction of fall/including: The intended direction of the fall. The natural lean of the tree.

Any MOusuallyheavylimb atru.cture. Surrounding trees and obstaQles. The wind direction and speed. Warnlngt Always observe the general condition of the tree. Look for decay and,rot in the trunk-If iUs rotted inside, it could snap and faD toward the operator while being cut.

Also look for broken or dead brandies which could vibrate loose and fall on the operator. When felling on a slope. the operator should stand on the up-hiIJ side Hpossible.


When felling in the vicinity of roads, railways and power lines, etc.. take extra precautions (see ill. 16). Inform the police, u1ifity company or railway au1hority before beginning to cu1.

Felling Instructions:

When felling, maintaJn a distance of at least· 2'h tree lengths from the nearest person (see ill. 17).

Then, establish.a path of escape and remove all obstacles. 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 a safe distance away from the tree, bu1 not on the escape path.



The noise of your engine may drown any warning call.

Firs1 clear the tree base and work area from interfering limbs end brush and clean its lower portion with an axe . (ill. 18).


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 directioh In whJchthe treewiiUaLIt Is made perpendicular to the Of f8n &net shOUld close to the groUnd as possible. Cut the felling notch to a dePth of abOut one-fifth to one-fourth of the trunk diameter (Ill 22). It should be In no ~ higher than it is deep. Make the felling notch very carefully.



Begin the felUng cut slightly higher than the feDing notch ora the opppsite side of tIMI tn!e (ill. .22). Then cut ho~l)I~h:toward$ ~ ~,n,g notch. Apply the chab1 saw with its spikes dlrecdy t;MlhIndthe ~ portion of wood and cut toward the notch (ill 23~ Leave approximately 'ho .o1.the ~ dlam_~ ~n.c;ul This is the hln.ge



Felling notch




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

_use you

Hinge......,........,H Felling notch


lose control of the direction of the faIL Drive wedges into the felfll'l9. ~t ~ ~ to COI1tmI the direction oftha ftdl.W~es should be ofw9Qd. Ught alloy or plastic-

never ~'~ Which can ~ kIckback,and






A'iways keep to the side of the f8Jling tree. When the tree starts to fall, shut off the engine. WIthdraw the bar and walk

: Be extremely careful with partially fallen trees which are poorly supported.

Forthe tteeHOriing methOd (HI. 24) make the first cut with the guide bar fanning tn toWard the· hinge. Then,usmgthe bumper spike as a pivot, reposition the saw for the next cut. Avoid reposftioning the saw more than necessary. When r8poSltiori!rig fci the 11Et~ ~ ic8ep 'the guide ~r engaged in the kerr to keep the fettlng cut strafght If the saW begins to pinCh. inSert a w8dge to open the cut. On the ~ cut. dO 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 ~

Sectioning Method

Tmber haVIng a diameter more than tWice the !ength Of the gUKJe bar reqUires the use of the plunge-(x.it method making th.e f8lHngcUt ..

away on the pre-planned escape path. Watch out for failing limbs.




warning! . Felling a tree that has diameter greater than the length of the guide bar requl~ use of either the sectioning or plunge-cut method. These methods' are extremely dangerous because they InvolVe the use of the nose of the guide bar and can result In kickback. Only property trained professionals should attempt· these techniqueS.




First. cUt a large. wide nOtch. Make a plunge- cut In the center of the notCh. . .. The- plunge cut is made with the guide' ~ nose. BegIn the plunge. cUt by 'applylitg the lower portiOn of the guide bei nose to the tree at an angle (ill. 25)~ Cut until the dePth of the kerf Is about the same as the width of the guide bar

~ . \A) 26"



(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. 00 not stand on a log while Ilmblng it - you may slip or the log may roll.



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. Warnings! 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 uphill side of the 109 (see Ill. 31). Watch out for rolling logs. 2. Cut only one log at a time.


3. Shattered wood should be cut very carefully. Sharp. slivers of wood may be caught and flung in the direction of the operator of the saw.


When cutting small iOgS~ Use 8SaWhorae-(iD. 32). NeVer permit another person to hold the log. Never hold the log with your leg or.foot.

5. Logs under straln,'require sPecial attention to prevent the saw trpm pinch1n.g•. The fifst cut·is made on the compression side to relieve the stresS on the log (see III. 33~ 34). The bucking cut is thEm made as shown. If the saw pinches, stop the engine and remove it from the log. 6. Only properly trained professionals should work in an area where the logs, limbs Bn.d roots are tangled (i.e. a

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


. 2. Cross art

warning! Always stop the engine and make sure that the chain is 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.


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.


Mounting Guide Bar and Chain Top: Backing off tensioning nut Bottom: Locating the guide bar

Top: FJtting the Ollomalic chain Bottom: Cutting edges face the bar nose

The guide bar and Oilomatic chain are supplied separately for safety reasons.

Locate slot of guide bar over the stud bolts (2) so that the 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).


Now back off the chain tensioning nU1 (4) - below the stud bolts (2) - by tuming the tensioning screw (5) counterclockwise to the end of Its thread.

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 hand. .


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.



Chain Oil

Fuel tank cap open

Oil filler cap open

You two-stroke engine is powered by a mixture of gasoline and engine 011. Only regular gasoline may be used. Never use high octane gasoline as it contains benzol which would permanently damage the carburetor diaphragms. Only use STIHL two-cycle engine oil or other branded twocycle engine oils for mixing. The mix ratio Is 1: 40 (1 part oil to 40 parts regular gasoline) with STlHL two-cycle engine oil or 1: 25 for other branded engine oils. Important: Always shake mixture In fuel can vigorously before fueling. -

The service I~e of the cutting attachment (Oilomatic chain andguide bar) depends on'good lubrication and the quality of the lubricating 011.

Never use waste

011 for this pUrPosel

Always use the chain lubricating oll .approved by STIHL and appointed dealers. If special chain lubricating oil is not available, one of the high-duty, Single grade engine oils listed below may be 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 refueling.

Helpers Handle Knocking out blanking plug

Top: TIghtening the clamp nut Center: Mounting hardware fitted on bumper spike 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 .


Starting Stop switcl1 away from "STOP "

" 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 trigger (3) first and then the starting throtUe lock (5).

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

Pressing the decompression valve

Top: 51.rting Center: Idle position Bottom: S10p switch In "STOP" position



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 decompression valve (7) and immediately disengage the starting 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.

• ,


; other points to beobserved:~~·l~..,~ engine: The choke lever:is mectianl~" &)ritJi~< the.·~­ Closi,cfWhen

retor's choke valve. The :dlOki:V8(Vltis the choke lever is 00 .. chOke t"skfWiiQ'n the ,CilOke lever is moveda~ay, from .~ ~;~:~, ~;::~~:,;,·', Yi~:,:;:,~~".:~:, :.::~1} : ~







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

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

.~~ .~'::: :·tt:~;~;·"; ~::,:.:51>'··: ·· :~ ;: ~( ~

If you moved tile choke lever 8Wlly!·frOJtli]hj ~~QiQke .. position after ~~j~Qgtnefired B!td~"~a~~~((:~·~ot run after sevEDI'" , His:alMQAU' ~ :In~SUCb a .~ ~t . -·'~"'~ ' .':~ '-'1":~~:-'. ·' · ,,;,"' ~'· "" : C8$~. re_'~,1ty9fUh!'~P!qg~~~~~s­ tionch~bY)~~gtht..~;~~~~~~n _t"


.. "


: ••

. the starter:WiIti:the




"StiU'remoYed '8rid:,1Iuf"8lO

~~11ii",·':~~;~~;sTbpT~~~. ~!p,i;y~q~ " , ~, ~:~ lever __ n "e mOv8 :~'~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"1hecarburetor's dlaphragm~pqtiJp only deDvers sufft~J~el after the engine haS b88atUmed over,several timeS:, '"

Oil quantity control 1 = Adjusting screw 2 = Counter nut Bottom: Loosening the counter nut


At the factory the chain oil supply of the oil pump is adjusted

to the standard cutting lengths of 53 em (20.9 in.) bar for 090, 090 AV, 90 em (35.4 In.) bar for 090 G. When using longer guide bars rt is possible to adjust the 011 quantity according to the bar length used by means of the provided adjustmem screw.

Before readjusting the oil quanttty remove Mer cover and fllter, flrst, however, close choke shutter (posrtion "0") so that no dirt can drop Imo the carburetor.

. Top: . Adjusting the oil quantity Bottom: Countering

The adjusting screw for regulating the oil quantity is located althe rear-wall of the 011 tank and is coumered with a hexagonal nut. Hold adjusting screw wlth fork wrench SW 10 and loosen counter nut wrth second wrench . .

When tuming the adjusting screw to the left - counter clockwise - more 011 Is supplied and when tuming to the right less 011 is supplied. Tuming the adjusting screw '/3 of a tum corresponds approx. to the necessary change of oil supply which is needed for the next longer bar length.


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.

The cutting attachment of a chain saw consists of the guide bar; saw chain and chain sprocket

GuJdebar The nose and underside of the guide bar are subject to a particularly high rate of wear. To avoid one-sided wear, tum the bar around every time you resharpen or replace the 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.

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 around !be nose. sprocket, repeat the procedure on the other side.

The sprocket nose bearing should be greased more often ff the cutting attachment is used in damp conditions, e.g. working in snow. AfII!r finishing cutting work the sprocket nose should be .thoroughly greased from both sides to force moisture out of the bearing and prevent corrosion.

Chain lubrication A minimum bar groove depth of 7 mm (0.28 in) must be maintained in order to prevent the drive Unks fouling the bottom of the groove (the heels of the culler and tie strap would no longer locate on the guide bar track).


This depth should be measured at the point where the bat is stressed mOst, I. e. the bar noee or: D'..!romatic bars and the area where most of the cuttiilg is done on RoliomaUc bars. The guide bar must be replaced .1f the minimum depth can not be maintained.

Never operate the chain saw without proper chain lubrication. Check operation of chain lubrication and level in 011 tank before starting work.

Hold chain saw with mounted cutting attachment over a light background. Take care, the Ollomatic chain must not touch the ground. i. e. keep H at least 20 em (8 in) clear of the ground. Run the engine with haH-throttle position. ff an increasing patch of oil can be seen, chain lubrication is operating correctly.

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 will begin to sag noticeabl)i"as Hwarms up to noimal operating temperature. The chaln must then be retensioned. However, the chain must be slackened off again immediately after shutting down the saw. This Is necessary to avoid contraction stress which would occur as the chain cools down to ambient temperature.

Every new chain has to be broken In for about 2 to 3 mInutes. Ample chain lubrication is essential during this period. After breaking in, stop the engine, check chain tension and adjust if necessary.

Correct chain tension The Ollomatic chain must always be slackened off after finishing cutting work A chain properly tensioned when ~ is warm would, when the temperature drops, be subjected to such great contnaction stresses that ~ would break and also damage the crankshaft and bearings.

A new chain must be retensloned more frequently than a used one util h has stretched fully.

Chain sprocket

The Oilomatic chain must, therefore, always be tensionedw~ the engine switched off - before you start cutting. Chain tension is correct In the cold condition when the chain fits snugly on the underside of the bar and can still be moved along the bar by hand. Extreme care must be !eken as ·the cutting edges are very sharp.

The stress and strain on the chain sprocket are particularly high. ~ the wear mar1


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 and counter hexagonal nut again with second wrench. Thereafter assemble air finer and filter cover again.

The air filter's function is to intercept dust and dirt in the combustion air and thus reduce wear on engine components.

In extreme cases (failure of automatic oil pump, heavy frost etc.) the use of the hand oiler assures sufficient chain lubrication.

Also during longer cutting periods with longer cutting lengths the chain is additionally supplied with lubricating all by activating the manual oller. Moreover, before starting we recommend to supply add~lonal lubricating oil to bar and chain by activating the manuai olier should the saw s~ idle at freezing temperatures for a longer period. Thus the cutting attachment is protected against excessive wear.

Clogged air Mers reduce engine power, increase fuel consumption and make starting more difficun. The airfilter must be cleaned dally-or morefrequently in very dusty operating conditions. Before removing the finer, close the choke vaive so that no dirt can get Into the carburetor. Unscrew the finer cover and take out the filter element. For daily cleaning it is sufficient to clean the filter with a soft brush. However, the complete' air fitter should be 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 ~ up before it drops too low.

It is advisable to carry a spare filter with you at ali Umes and clean the dirty finer in the workshop.

Carburetor 1




High speed adjustment screw 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:

The cartluretor Is adjusted at the factory foy maximum performance and most econOmic fuel consumption under average local atmospheric conditions. When working at high altitudes (mountains) or near sea level the carburetor may need to be readjusted. This must be done with two aQjustment screws and the Idle speed regulating screw.

Tum idle speed adjustment screw slightly counter-clockwise.

Engine runs erratically at Idle speed: Adjust at low speed adjustment screw. Tum clockwise for leaner mixture or counter-clockwise for richer mixture.

Basic adjustment of the carburetor.

Low speed adjustment screw (L): long, 1 tum open

Gautlon: The setting of the high-speed adjustment screw affects the engine's maximum off-load speed, ~ ~ Is set too lean (adjustment screw turned too far clockwise), the maximum permissible engine speed of 6000 r.p.m. will be exceeded. This can resu~ in engine damage brought about by insufficient lubrication In particular.

Take this basic adjustment as a guide when readjusting your carburetor. Check carburetor adjustment with warm engine and a clean air filter. Carefully screw In both adJustme.nt screw until snug litl

Apart from minor readjustments, you should not attempt carburetor adjustments or repairs yourself. Entrust such work to STIHL Service. In most areas you will find STIHL Service Shops w~h trained specialists and the tools necessary for expert servicing.

High speed adjustment screw (H): short, 1 tum open


Replacing the chain sprocket 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 threadloosen 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 1109 890 4401.

•• - "

Gear lubricant 090 G Top: loosening Ill. hex. nut (090 G) Bonom: Pulling off the chain sprocl
Opened gear COV9( 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 horizontal 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 taking care that the key groove Is guided properly over the key. Then place washer and nut onto the shaft, countemold chain sprocket with pliers and strongly tighten hex. nut.

At least every 6 months the all In the gear must be renewed . Put machine with gear cover pointing up, screw outmanuai oiler and remove gear cover. Empty the old oil and pry oft 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. Remove locking screw and mount spark plug again.

cover and tighten. Th,en screw in manual oiler. Remove locking screw and fill In 0,151 (0.32 pt.) all.


Rewind starter loosening the fastening screws

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 Is hooked properly Into the loop of the rewind spring.

Top: Prying oft the ret:alnerwasher Bot\om: Component parts

Installed rewind spring

Now reinstall the remaining parts of the rewind starter in . - the correct sequence as shown on the illustration. It is important that the two fiber material washers have to be inserted in front of and behind the friction shoe system_ The friction shoe system is mounted property when the lugs at the spring retainers point In clockwise direction. Secure rope. with retaining washer and tension rewind spring.

Replacing a broken rewind spring The spare spring Is supplied ready lor Installation complete with spring housing and should be applied with a few drops of oil belore mounting. Insert recoil spring wHh spring housing - housing bottom pointing downwards - in the Ian housing and hook outer spring lug into the cast lug 01 the fan housing. Should the 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 spring with washer and mount rope pulley again.

Tensioning of rewind spring

Tensioning 01 rewind spring Hold the uncoiled rope close to the pulley and Insert the rope ·into the notch at the periphery of the rope pulley. Now tum rope pulley by means of the rope 4-5 turns In clockwise direction - to the right - thereby tensioning the rewind spring. Hold rope pulley, rearrange twisted rope and pull out completely.

Release rope pulley and slowly let starter rope go so that it colis itsen automatically onto the rope pulley by the attained pretenSion. The rewind spring is properly tensioned ij the starter grip Is tightly pulled into rope bushing and does not tin sideways. At fully pulled out starter rope one should sti.ll be able to tum the pulley at least ';' tum until maximum spring tension Is reached. Otherwise pull out starter rope, hold pulley and uncoil rope by·one layer. Then remount Ian cover and on 090 G handle tube support.

Excessive spring tension will cause breakage 01 the spring.


Maintenance Chart

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

jf Jt!cai f ... "iii



Master Control, dep8ncfing on model

ChaIn brake Filter In fuel tank Fuel tank Chain oil tank Chain lubrtcatlon

Check operation Check operation Clean Clean wire fifter FI8pIace felt Clean

Clean Check Inspect, also check sharpness QIe.CI( chaln tension Sharpen Inspect (wear, damage) Clean and tum aver

Saw chain





S :::


Clean Replace

Cooling InIe1s


Cylinder fins

Clean Check Idle adjustmentchain must not tum Readjust Idle Readjust eleCtrode gap

Rubber vibration buffers Spark'arrestor screen


Chain catching bolt



x x


x ·x x x x


x x x


29 39






Spark plug








ChaIn sprocket

~ accessible SCI'8W8 and nuts adjusting screws)








I Ii i



Throttle !Jigger, safety tt'llvttSe lock. stop switch.

Guide bar


Visual inspectlon (condition, leaks)

Complete machina





30 30

x x x x

x x x x



Inspect To be replaced onlY by STlHL Dealer Inspect. depending on model Clean or replace Check Replace



x x x

3t 3t

Specifications 090, 090 AV

Specifications 090 G

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

106 cms (6.36 eu. in) 58 mm (2.3 in) 40 mm (1.57 in)

Ignition System

Type: Ignition timing: Breaker point gap: Spark plug:

Flywheel magneto 2.9-3.1 mm (0.114-0.122 in) before T. D.C. 0.35-0.45 mm (0.013-0.018 in) BoschWSR6F Champion RCJ 6 Y

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

Chain: Chain sprocket Chain lubrication: Oil capacity:

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

Weights 090 with 53 em (21 In) bar and chain: approx. 13.9 kg (30.6Ib) 090 AV with 53 em (21 in) bar and chain:·approx. 14.6 kg (32.2 [b) 090 G with 90 em (35 In) bar and chain: approx. ',68kg (37.1 Ib)

Flywheel magneto 2.9-3.1 (0.114-0.122 in) beforeT.D.C. 0.35-0.45 mm (0.013-0.018 In) BoschWSR6F Champion RCJ 6 Y All position diaphragm carburetor 1.21 (2.5 US pt) Flocked wire mesh element Mix ratio 1: 25 with SAE 30 two-cycle engine oil; 1: 40 with STlHL two..cycle engine oil 90, 105, 120, 150 em (35, 41, 47, 59 in) , use helpers handle on guide bars of 105 em (41 In) and longer 112" (12.7 mm) pitch 6-tooth Fully automatic with oil feed control and supplementary, unit-mounted hand pump 0.531 (1.1 US pt)

Gearbox Type: Spur gear Reduction ratio: 2: 1 Lubrication: HD SAE 30 engine oil 011 capacity: 0.151 (0.32 US pt)


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 mention 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 Guide bar part number Sprocket part number


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 using original snHL spare parts.

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. chipper 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 rivet 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 normal 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 sharpening a chain. They are explained below.

Filing angle The filing angle for Rapid-Standard, Rapid-Micro and Topic-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 timber, 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 chain to run roughly and unevenly as well as accelerate the rate of wear and increase the risk of breakage.

t·t 39

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 Rapid-Micro Raptd-Super

Topic-Micro Topic-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 pr0perly with a suitable STlHL sharpening tool.


Chain pitch '



' .325" (8.25mm) Ra,:rid'~.r (4.8mm)·08,141, 80ss . ' ~25" (8.25·mm) Topic %f(4~o.,mmFO)1,4 242 ~ . W .. (9.32mm)·RaPid¥ltf(4~8mm)Q8114118088 W (9.32 mm) Topic ~ (4.0 mm) 0814 242 ~ .404" (10~ n'lm) ~tf (4.8 mm) 0811 411 8088 W (12.7r.nin) tAli (6.3mm) 0811411 811~


OnlyspeciaJ saw chain flies may be used for sharpening and they must match the chain concerned ·(basic .type, pitch). The shape and cut of machinists' flies makes them unsuitable for saw chain. It is best to use the speciaJ chain fllewith :aflle holder or other flUng-aid. Always file from the inside to the outside of the CIdIer. If yoU sharpen the chain while It Is on the bar, increase chain tension before filing and reset It to correct tension afterward.

All cutters must be filed to the same length. Since the top plate slopes downward to the rear (clearance angle), the


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






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-Super chains.

cutter heights will be uneven ~ the cutter lengths are different. If the cutters are not all the same height the chaln will run roughly and eventually break. I's ~ is very Important to.achieve unijonm cutler lengths, ~ is best to measure them with a slide caliper. Find and sharpen the shortest cutter first and then use ~ as a master for all the others, J. e. all cutlers must be filed back to the same length as the mester cutler. Sharpen all the cutters on one side of the chaln first and then repeat the procedure on the other side. The file must be held level for Rapld-standard, Rapid-

File evenly and steadily and note that the file only sharpens on the forward stroke- Uft the file off the cutter on the backstroke. Make sure you do not touch the tie straps and drive links with the file. Use a piece of hardwood to remove bunrs from the cutting edge. Importam: Sharpen the chain frequemly and take away as little material as possible. Two or'three strokes of the file are usually suffciem to the keep the chain sharp. variations In angles and the lengths of the cutlers cannot be completely avoided during manual sharpening. For this reason the chaln should be restored to ~ Original condition with a workshop chain sharpener (STIHL USG, SnHL FG 2)' after rt has been resharpened about five times by hand.


Top: Table of recommended depth gauge settings Center: Depth gauge setting Bottom : Filing down depth gauge (Topic chain) Depth gauges The depth gauge determines the height at wh ich the cutter enters the wood and thus the thickness of the chip removed. The cutting capacity and life of a saw chain are therefore influenced by the distance between the depth gauge and the cutting edge, i. e. the depth gauge setting. This setting varies according to chain p~ch and must be checked with the appropriate filing gauge.

Chain pitch


Filing gauge

.325" (8.25 mm)

0.65mm .

1110 893 4000




.404" (10.26 mm)


1106 893 4000



1106 893 4000

1.2 mm

1106 B93 4010

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 remove filings or grinding dust. Then lubricate the chain by

(12.7 mm)

090 G chain saw

W The best cutting resu~ are obtained with the settings listed in the table. However, the depth gauge setting may be increased by 0.2 mm for cutting scftwood in mild weather conditions.

(9.32 mm)

(12.7 mm)

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 immerse it In an oil-paraffin bath.

Carefully examine chain for cracks in'the links or damaged rivets while you are sharpening and cfeanlng it. Any damaged or worn parts' be replaced. The new parts must be reworked to match the shape and size of the original parts.


Chain repairs can be carried out With the STIHL handheld chain breaking and riv~ spinning tool, the STlHL NG 1 or NG 5 rivet spinners and the STIHL NG 4 chain breaker. >

Chain pitch inch(mm)

Chain Rapid~Micro

File holder Part No.

.325 .325 .325 .325

(8.25) (8.25) (8.25) (8.25)

RaPid-8uper Topic-Micro Topic-Super

% % % % %

(9.32) (9.32) (9.32) (9.32) (9.32)

Rapid-siandard Rapid-Micro Rapid-Super Topic-Micro Topic-Super

56057504326' 5605 750 4326 5605 750 4336 5605 7504321 5605 750 4351

Rapid-Standard Rapid-Micro Rapid-Super

5605 750 4326 5605 750 4326 5605 750 4336

.404 (10.26) .404 (10.26) .404 (10.26)

• 5605 750 4326 5605 750 4336' 5605 750 4321 5605 7504351

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 types of chain. The FG 1 filing tool attaches to the guide bar and sharpens all types of chain. The STlHL FG 2 Filerlte and USG universal electric sharpener are workshop tools suitable for sharpening ail types of chain.



1 .. 85° side plate angle 2 1:1 70° side plate angle 3 ... aoo and 90° side plate angles 4 35° filing angle (Standard und Micro) 5 a 3Qofiling angle (Supelj 6 a Depth gauge setting 7 ... Groove cleaner and scale for cutter length and groove depth Q

The filing gauge is a universal tool for checking the filing and side plate angles as well as the depth gauge setting and outter length. It can also be used for oleaning the guide . bar groove and oil inlet hole and measuring the groove depth. The following fiUng gauges are available: 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 (0,8 mm depth gauge setting).

1 CI Sprocket pitch 2 .,. Chain pitch

3 a Drive link gauge 4 .,. Groovewidth 5 ... File diameter 6 III Lug for cleaning bar groove and oil inlet hole

The reference gauge 0000 893 4105 is used to detennine the distinguishing characteristics of saw ohains and guide bars. Furthermore, it can be used to olean the guide bar groove and oil inlet hole as well as oheck the diameter of the . ohain sharpening file.

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