Stihl 009 User Manual
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Stihl 009 User Manual

Stihl 009 User Manual

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STIHL 009, 010, 011
SERVICE MANUAL
STIHL 009, 010, 011
FOREWORD
This Service Manual covers model 010
chain saws up to machine number
7 900 000 as well as later machines
unless technical information bulletins
have been issued in the meantime
with updated repair procedures.
Models 009 and 011 have substantially
the same constructional features as
model 010 chain saws. This Service
Manual can therefore be used for the
009 and 011 chain saws as well.
In the event of faults it is quite possible
that a single fault may have several
causes. It is therefore advisable to
consult the "Troubleshooting Chart"
in each chapter when tracing faults.
We also recommend that you make
use of the exploded views in the
illustrated parts lists when carrying out
repair work.
This service manual and all technical
information bulletins are intended
exclusively for the use of STIHL
servicing dealers and staff and must not
be passed on to third parties.
STIHl
Andreas Stihl
Postfach 1760
D-7050 Waiblingen
Repair work is made considerably
easier if the chain saw is mounted on
assembly stand 5910 850 3100. The
saw is easily secured to the stand by
means of the bar mounting stud and
collar nut.
While on the assembly stand the chain in several languages and can be
saw can be swivelled into any required ordered by quoting the appropriate
position within a certain range to suit
the repair in question. This not only
has the advantage of keeping the
component in the most convenient
position for the repair but also leaves
both hands free for the work and thus
effects a considerable time saving.
SPECIAL TOOL MANUAL
Our special tool manual illustrates
and lists the part numbers of ail
available machine-related tools as
well as general purpose tools for all
machines.
The special tool manual is available
part number listed hereunder.
German
0455 901 0023
English
0455 901 0123
French
0455 901 0223
Spanish
0455 901 0323
Yugoslav
0455 901 0423
Swedish
0455 901 0523
Italian
0455 901 0723
Portuguese
0455 901 1223
1

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Do you have a question about the 009 and is the answer not in the manual?

Questions and answers

Bennie Jordan
February 5, 2025

What can be wrong if the chain oiler is oiling way too much.

0
1 comments:
Mr. Anderson
May 14, 2025

The chain oiler on a Stihl 009 could oil excessively due to a torn or ripped gasket on the pump or a damaged rubber boot. These issues can cause the pump to leak or deliver too much oil. Additionally, the oil delivery rate increases with engine speed, so if the saw idles too high, it could also cause excessive oiling.

This answer is automatically generated

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Related Manuals for Stihl 009

Summary of Contents for Stihl 009

  • Page 1 010 chain saws. This Service Manual can therefore be used for the 009 and 011 chain saws as well. In the event of faults it is quite possible that a single fault may have several causes.

  • Page 2: Table Of Contents

    STIHL 009, 010, 011 CONTENTS Specifications Installation of 4.5.2 Adjusting Breaker- Crankshaft Controlled Ignition Engine - Assembly of Magneto Edge Gap Fuel System Crankcase on Breaker- Ignition System Leakage Testing the Controlled Ignition Tightening Torques Crankcase Cutting Attachment 3.8.1 Pressure Test Weights 3.8.2...
  • Page 3 STIHL 009, 010, 011 Fuel System Construction and Operation of Carburetor 8.1.1 Operation of Fuel Pump 8.1.2 Operation of Carburetor Troubleshooting Chart Leakage Test (Pressure Test) on Carburetor Disassembly of Carburetor Repair of Carburetor Carburetor Adjustment 8.6.1 Notes for Fine Adjust-...

  • Page 4: Specifications

    STIHL 009, 010, 011 SPECIFICATIONS 1.1 Engine Single cylinder two-stroke engine with specially processed cylinder bore Displacement 009, 010: 37 cm³ (2.26 cu. in) Bore 009, 010: 36 mm (1.42 in) Displacement 011: 41 cm³ (2.50 cu. in) Bore 011: 38 mm (1.50 in)

  • Page 5: Ignition System

    STIHL 009, 010, 011 Fuel mixture: Regular grade gasoline and branded two-cycle engine oil Mix ratio 1:40 with STIHL two-cycle engine oil: 1:25 with other branded two-cycle engine oils Air filter: Large area felt mat Ignition System Type: Breaker-controlled magneto...

  • Page 6: Cutting Attachment

    011 AV Dry powerhead with 30 cm bar and chain: 4.3 kg 4.6 kg 4.7 kg (9.51 b) (10.1lb) (10.4Ib) Special Accessories STIHL repair kit 009, 010, 011 1120 900 5000 Set of gaskets 009, 010, 011 1120 007 1050...

  • Page 7: Clutch, Chain Drive And Chain Brake

    STIHL 009, 010, 011 CLUTCH, CHAIN DRIVE AND CHAIN BRAKE Construction and Operation 2.1.1 Clutch and Chain Sprocket Clutch with cranked U-plate in position Component parts of clutch The transmission of power from the engine to the saw chain is effected via a centrifugal clutch which has no linings.

  • Page 8: Chain Brake

    STIHL 009, 010, 011 2.1.2 Chain Brake The chain brake is a spring-loaded The chain brake is disengaged by The chain brake is engaged by band brake without any friction linings. pulling the hand guard back toward moving the hand guard toward the Its main components are the brake the handlebar.

  • Page 9: Repair

    STIHL 009, 010, 011 Repair 2.3.1 Disassembly and Assembly of Clutch Top: Top: Locking screw 1107 191 1200 Wrench 1113 890 3600 Bottom: Bottom: Locking screw in position Unscrewing the clutch Counterbored side of clutch washer and stub of crankshaft with clean gasoline.

  • Page 10: Disassembly Of

    STIHL 009, 010, 011 2.3.2 Disassembly of 2.3.2.1 Disassembly of Chain Brake Chain Brake Top: Detaching tension spring Top: Brake band, brake lever and tension spring in Center: position Removing retaining washer Bottom: Bottom: Fitting tension spring with installing tool...

  • Page 11: Engine

    STIHL 009, 010, 011 ENGINE Construction Series 010 chain saws are powered The crankcase is a two-part pressure The connecting rod is supported by by an air-cooled, single cylinder two- die casting made of a magnesium cylindrical rollers, i. e. without a stroke engine.

  • Page 12: Exposing The Cylinder

    STIHL 009, 010, 011 Exposing the Cylinder Disassembly of Cylinder and Piston Top: Top: Top: Unscrewing the fan housing Removing the handle moulding Removing flat head screw Bottom: Bottom: Bottom: Unscrew the muffler Removing hexagon nut from handlebar Removing cylinder base...

  • Page 13: Assembly Of Piston

    STIHL 009, 010, 011 Top: Top: Top: Wooden assembly block 1108 893 4800 Removing wire retainer Clamp 1120 893 9100 Bottom: Bottom: Bottom: Assembly block fitted between crankcase Pressing out piston pin Clamp in position and piston with drift 1114 893 4700...
  • Page 14 STIHL 009, 010, 011 Assembly of Piston and Cylinder Tightening cylinder base screws with Arrow must point toward flywheel Fitting the cylinder torque wrench As there are no longer any matching Fit new cylinder gasket on the crank- categories to observe the piston and case.

  • Page 15: Disassembly Of Crank

    STIHL 009, 010, 011 Disassembly of Crank- case - Removal of Crankshaft Top: Top: Removing key Driving out the crankshaft Center and bottom: Bottom: Removing the hand guard Knocking back cylindrical pins Knocking out oil seal To remove the crankshaft, first drain the fuel and oil tanks.

  • Page 16: Installation Of Crankshaft - Assembly Of

    STIHL 009, 010, 011 Installation of Crankshaft - Assembly of Crankcase Top: Cleaning sealing faces Center: Needle sleeve correctly positioned Driving out needle sleeve Bottom: with press arbor 1120 893 7200 Pressing in needle sleeve If the old crankcase is used again, carefully clean the sealing faces.
  • Page 17 STIHL 009, 010, 011 Top: Top: Press sleeve 1120 893 2400 Cylindrical rollers held in position by grease Bottom: Bottom: Pressing oil seal into position Clamp 1120 893 9100 in position Cutting away gasket web at cylinder opening during assembly and the cylindrical rollers dropping out of the crankshaft groove.

  • Page 18: Leakage Testing The Crankcase

    STIHL 009, 010, 011 Leakage Testing the Crankcase Top: Carburetor and crankcase tester 1106 850 2900 Bottom: Removing gasket web at inlet port Vacuum pump 0000 850 3500 Then insert and tighten down the flat head screws to a torque of 4 - 5 Nm (0.4 - 0.5 kpm).

  • Page 19: Pressure Test

    STIHL 009, 010, 011 3.8.1 Pressure Test Top: Sealing plate 1120 855 8100 and Top: test flange 1120 855 4200 Test flange 1120 855 4215 in position Bottom: Bottom: Exhaust port sealed Test flange 1118 850 4210 secured in position...

  • Page 20: Vacuum Test

    STIHL 009, 010, 011 3.8.2 Vacuum Test 3.8.3 Replacing the Oil Seals Leakage test with vacuum pump Puller 0000 890 4400 in position Oils seals tend to fail when they are must be replaced even if no leaks The oil seals can be replaced with- subjected to a vacuum.

  • Page 21: Ignition System

    STIHL 009, 010, 011 IGNITION SYSTEM Description of Operation Construction The 010 is equipped with a breaker- Every magneto ignition system ope- voltage is principally depended on the controlled magneto ignition system rates on the principle of magnetic strength of the primary current which which requires neither a battery nor induction.

  • Page 22: Breaker-Controlled Magneto Ignition

    STIHL 009, 010, 011 4.2.1 Breaker-Controlled Magneto Ignition Diagram of ignition system: 4 Contact breaker 1 Flywheel 5 Condenser 2 Permanent magnet with north and 6 Spark plug south poles and pole shoes 7 Ignition stop switch 3 Ignition armature with primary and...

  • Page 23: Troubleshooting Chart

    STIHL 009, 010, 011 Troubleshooting Chart Spark plug terminal firmly seated on spark plug? Remove spark plug. Press terminal firmly onto spark Is it in good condition? plug and fit spring if necessary. Clean spark plug and reset electrode gap.

  • Page 24: Function And Repair Of Components

    STIHL 009, 010, 011 Function and Repair of Components 4.4.1 Spark Plug Troubleshooting on the ignition The high-tension pulse generated in alternative to the standard Bosch the ignition system is fed to the spark system should always begin at WSR 6 F (formerly WKA 200 TR 6).

  • Page 25: Ignition Lead

    STIHL 009, 010, 011 4.4.2 Ignition Lead Checking electrode gap Resetting electrode gap with Bosch with feeler gauge spark plug gauge Pulling out leg spring Never use a steel wire brush for by pulling the rewind starter. The ignition lead feeds the high-...
  • Page 26 STIHL 009, 010, 011 4.4.3 Ground Lead Contact Top: Top: Ignition lead inserted through Spring strip of ignition stop switch terminal pushed out of slot Bottom: Bottom: Screwing ignition lead onto armature Fitting leg spring Removing ignition stop switch The new ignition lead must have a length of 370 mm.

  • Page 27: Flywheel

    STIHL 009, 010, 011 4.4.4 Flywheel Top: Locking screw 1107191 1200 in position Bottom: Releasing hexagon nut Removing the contact spring The flywheel has several functions. It accommodates the permanent mag- net for the ignition system with a north and south pole (polarized in the engine's normal direction of rotation).

  • Page 28: Ignition Armature

    STIHL 009, 010, 011 4.4.5 Ignition Armature Top: Releasing flywheel with puller 1116 893 0800 Bottom: 1 = Primary connection Tightening hexagon nut with 2 = Secondary connection torque wrench Key correctly positioned 3 = Ground connection On the ignition armature the primary...

  • Page 29: Resistance Test On Primary Winding

    STIHL 009, 010, 011 4.4.5.1 Resistance Test 4.4.5.2 Resistance Test 4.4.5.3 Disassembly on Primary Winding on Secondary Winding and Assembly Top: Removing the contact set Bottom: Resistance test on primary winding Resistance test on secondary winding Unscrewing the ignition armature...

  • Page 30: 4.4.6 Condenser

    STIHL 009, 010, 011 4.4.6 Condenser Top: Setting gauge 1111 890 6400 Center: Securing the armature Bottom: Checking condenser with ohmmeter Pushing armature away from flywheel Checking air gap with feeler gauge 5910 850 4800 The condenser is wired in parallel with To reassemble, connect up primary the contact breaker.

  • Page 31: 4.4.7 Contact Set

    STIHL 009, 010, 011 4.4.7 Contact Set Top: Removing contact set and cable clamp Bottom: Removing mounting screw Discharging the condenser The contact breaker set consists of a fixed contact, which is connected to ground, and a moving contact breaker...

  • Page 32: Ignition Timing

    STIHL 009, 010, 011 Ignition Timing Top: Cylindrical pin on contact set Bottom: Locating hole in crankcase Checking breaker point gap The ignition timing on the breaker- controlled magneto ignition system must be set to 2.0 mm before T D.C.

  • Page 33: Checking Breaker

    STIHL 009, 010, 011 4.5.1 Checking Breaker Controlled Ignition Top: Dial gauge with holder 1110 890 8600 and Top: tracer pin 1107 894 3000 Dial gauge set to "O" Bottom: Bottom: Holder in position Ignition timing unit ready for test...

  • Page 34: Adjusting Breaker-Controlled Ignition

    STIHL 009, 010, 011 4.5.2 Adjusting Breaker- Magneto Edge Gap on Controlled Ignition Breaker-Controlled Ignition Resetting breaker point gap The position of the magnet at the lated. None of these values can be point of current interruption, i.e. altered without affecting the others.

  • Page 35: Rewind Starter

    STIHL 009, 010, 011 REWIND STARTER Construction and Operation The withdrawn starter rope is auto- The rewind starter mechanism is loaded rewind spring, rotates the matically rewound onto the rope rotor mounted on the starter post in the rotor when the starter grip is pulled.

  • Page 36: Disassembly

    STIHL 009, 010, 011 Disassembly Replacing the Starter Rope Top: Top: Starter rope secured in rope rotor Pawl in position Bottom: Bottom: Unscrewing the fan housing Special knots Fitting the spring clip First unscrew the fan housing together with the rewind starter. Then release tension on rewind spring.

  • Page 37: Replacing The Rewind Spring

    STIHL 009, 010, 011 Replacing the Tensioning the General Maintenance Rewind Spring Rewind Spring Rewind spring in position Tensioning the rewind spring If the starter rope action becomes very stiff and it rewinds very slowly or not completely, it can be assumed that the rewind starter is mechanically in order but plugged with dirt.

  • Page 38: Av Handle System

    STIHL 009, 010, 011 AV HANDLE SYSTEM Repair Construction and Operation Top: Removing flat head screw Bottom: Position of vibration dampers Unscrewing vibration damper with bracket Unscrewing the hexagon nut On handlebar The anti-vibration handle system re- duces engine and cutting attachment Unscrew the hexagon nut.

  • Page 39: Chain Lubrication

    STIHL 009, 010, 011 CHAIN LUBRICATION Construction and Operation of Oil Pump Schematic of oil pump Top: 1 = Filter Intake stroke 2 = Feed bore 3 = Plunger with diaphragm Bottom: 4 = Pulse chamber Delivery stroke 5 = Compression spring and plunger fills with chain oil.

  • Page 40: Troubleshooting Chart

    STIHL 009, 010, 011 Troubleshooting Chart In the event of difficulties with the chain oil supply, always investigate and rectify the other possible sources of faults before disassembling the oil pump. Remedy Fault Cause Fill up with oil No oil supply to chain...

  • Page 41: Oil Tank/Tank Vent

    STIHL 009, 010, 011 Oil Tank/Tank Vent Notes on Repair Chain oil supply system Split pin in vent hole sure in the oil tank. This is necessary because the pump would not otherwise operate, i. e. the airtight seal provided by the oil filler cap...

  • Page 42: Disassembly And Repair Of Pump Housing

    STIHL 009, 010, 011 Disassembly and Repair of Pump Housing Top: Top: Removing retaining ring Removing the oil pump Bottom: Bottom: Assembly sequence-diaphragm, compression Removing plastic washer spring and pump cover Disconnecting delivery hose The filter can also be washed in clean gasoline.

  • Page 43: Fuel System

    STIHL 009, 010, 011 FUEL SYSTEM Construction and Operation of Carburetor The all-position diaphragm flow from the pump chamber into the the diaphragm against the pump carburetor consists of the fuel pump diaphragm chamber. The needle chamber and exerts pressure on the and the carburetor body.
  • Page 44 STIHL 009, 010, 011 Top: Top: Starting position Changing from idle to part or full-throttle position Bottom: Idle position Bottom: Full-throttle position 1 - Pulse nipple 2 - Inlet valve open 9 - Throttle valve 3 - Fuel intake 10 - Secondary idle jet...

  • Page 45: Troubleshooting Chart

    STIHL 009, 010, 011 Troubleshooting Chart Remedy Fault Cause Inlet valve not sealing. Remove and clean or Carburetor floods – Foreign matter in valve seat replace inlet needle engine stalls or cone damaged Helical spring not located on Remove inlet control lever and...
  • Page 46 STIHL 009, 010, 011 Remedy Fault Cause Clean jet bores and blow Engine stalls at idle speed Idle jet bores or ports clogged out with compressed air Turn low-speed adjustment screw Idle jet too "rich" slightly clockwise (see Carburetor Adjustment) Set idle speed screw correctly Idle speed screw incorrectly set –...

  • Page 47: Leakage Test (Pressure Test) On Carburetor

    STIHL 009, 010, 011 Leakage Test (Pressure Test) on Carburetor Bottom: Tester connected Correct position of fuel line Removing the carburetor The carburetor can be tested for First remove the filter cover and filter leaks with the carburetor and plate and pull the fuel line off the car- crankcase tester 1106 850 2900.

  • Page 48: Repair Of Carburetor

    STIHL 009, 010, 011 Repair of Carburetor Top: Removing fuel pump end cover Bottom: Taking out the fuel strainer Removing metering chamber cover Removing inlet needle be lifted out with a screwdriver and recess in the metering diaphragm washed in clean gasoline. Always chamber.
  • Page 49 STIHL 009, 010, 011 Top: Top: Removing adjustment screws Locating studs on carburetor body Bottom: Bottom: Removing the plate Hole in metering chamber cover Locating studs on end cover end cover must face away from the adjustment screws. Refit the fuel strainer, pump dia- phragm, gasket and fuel pump end cover and screw down firmly.

  • Page 50: Carburetor Adjustment

    STIHL 009, 010, 011 8.6.1 Notes for Fine Adjustment of Carburetor Adjusting idle speed screw 1 = High-speed adjustment screw 2 = Low-speed adjustment screw (Filter cover must be removed for this adjustment) 3 = Idle speed screw Do not interchange these adjustment...

  • Page 51: Fuel Line

    STIHL 009, 010, 011 Fuel Line Tank Vent Withdrawing the pickup body Removing the felt bar Tank vent in position Trouble-free operation of the The diaphragm pump draws fuel out The tank vent consists of a tube and a carburetor depends on the fuel tank of the fuel tank and into the carburetor grub screw.

  • Page 52: Air Filter And Choke Valve

    STIHL 009, 010, 011 Air Filter and Choke Valve Top: Choke slide in "CHOKE" position Bottom: Removing filter cover Pressing down the valve plate The air filter's function is to intercept and retain dust and dirt in the intake air and thus reduce wear on engine components.

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