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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
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Summarization of Contents

Specifications
Engine Specifications
Detailed engine specifications including displacement, bore, stroke, and torque.
Fuel System Specifications
Carburetor type, adjustment, and fuel capacity specifications.
Ignition System Specifications
Magneto ignition type, gaps, timing, and spark plug details.
Tightening Torques
Specifies torque values for various fasteners and components.
Cutting Attachment Details
Details guide bars, chain types, sprocket, and chain speed.
Weights
Dry powerhead and unit weight with 30 cm bar and chain.
Special Accessories
Lists available repair kits and gasket sets for models.
Clutch, Chain Drive and Chain Brake
Construction and Operation
Explains how the clutch and chain brake are constructed and operate.
Clutch and Chain Sprocket
Details the centrifugal clutch mechanism and its engagement speed.
Chain Brake
Describes the spring-loaded band brake and its actuation.
Troubleshooting Chart
Lists common faults, causes, and remedies for the clutch and chain brake system.
Repair
Provides instructions for repairing the clutch and chain brake systems.
Disassembly and Assembly of Clutch
Step-by-step guide for removing and installing the clutch assembly.
Disassembly of Chain Brake
Instructions for taking apart the chain brake components.
Assembly of Chain Brake
Steps for reassembling the chain brake mechanism.
Engine
Engine Construction
Describes the air-cooled, single cylinder, two-stroke engine construction.
Engine Troubleshooting Chart
Lists common engine faults, causes, and remedies.
Exposing the Cylinder
Steps to remove covers and access the cylinder for inspection.
Disassembly of Cylinder and Piston
Detailed instructions for removing the cylinder and piston assembly.
Assembly of Piston and Cylinder
Step-by-step guide for installing the piston and cylinder.
Disassembly of Crankcase - Removal of Crankshaft
Instructions for splitting the crankcase and removing the crankshaft.
Installation of Crankshaft - Assembly of Crankcase
Guide for fitting needle sleeves, oil seals, and assembling crankcase halves.
Leakage Testing the Crankcase
Method for testing crankcase airtightness using vacuum and pressure testers.
Pressure Test
Detailed procedure for performing a pressure test on the crankcase.
Vacuum Test
Procedure for conducting a vacuum test to check oil seals.
Replacing the Oil Seals
Steps for removing and installing new oil seals on the crankshaft.
Ignition System
Ignition System Construction
Explains the breaker-controlled magneto ignition system and its components.
Ignition System Operation
Details how magnetic induction generates voltage in the ignition system.
Breaker-Controlled Magneto Ignition
Explains the operation of the breaker-controlled magneto ignition system.
Ignition System Troubleshooting Chart
Provides a flowchart for diagnosing ignition system faults.
Function and Repair of Ignition Components
Covers the function and repair of various ignition system parts.
Spark Plug
Discusses spark plug function, types, and appearance interpretation.
Ignition Lead
Explains the ignition lead's role and how to check/replace it.
Ground Lead Contact
Details the ground lead connection and the ignition stop switch function.
Flywheel
Explains the flywheel's functions, including magnet housing and starting torque transmission.
Ignition Armature
Describes the ignition armature, its connections, and testing methods.
Resistance Test on Primary Winding
Procedure for testing the primary winding resistance of the ignition armature.
Resistance Test on Secondary Winding
Procedure for testing the secondary winding resistance of the ignition armature.
Disassembly and Assembly of Ignition Armature
Steps for removing and reinstalling the ignition armature and contact set.
Condenser
Explains the condenser's function in suppressing sparking and how to test it.
Contact Set
Details the contact breaker's function, wear, and replacement procedure.
Ignition Timing
Procedure for setting the ignition timing and adjusting the breaker point gap.
Checking Breaker-Controlled Ignition
Method for checking ignition timing using a dial gauge and timing unit.
Adjusting Breaker-Controlled Ignition
Procedure for adjusting ignition timing based on dial gauge readings.
Magneto Edge Gap
Explains the magneto edge gap and its influence on ignition performance.
Rewind Starter
Construction and Operation
Describes the rewind starter mechanism, its components, and how it works.
Troubleshooting Chart
Lists common rewind starter faults, causes, and remedies.
Disassembly
Instructions for taking apart the fan housing and rewind starter assembly.
Replacing the Starter Rope
Step-by-step guide for installing a new starter rope.
Replacing the Rewind Spring
Instructions for replacing the rewind spring in the starter mechanism.
Tensioning the Rewind Spring
How to properly tension the rewind spring for correct operation.
General Maintenance
Tips for maintaining the rewind starter, including cleaning and lubrication.
AV Handle System
Construction and Operation
Explains how the anti-vibration system reduces engine vibrations for the operator.
Repair
Instructions for repairing or replacing vibration dampers in the AV handle system.
Chain Lubrication
Construction and Operation of Oil Pump
Details the oil pump's construction and how crankcase pressure operates it.
Troubleshooting Chart
Lists common chain oil supply faults, causes, and remedies.
Oil Tank/Tank Vent
Describes the oil tank and vent system's function and maintenance.
Notes on Repair
General notes and precautions for repairing the oil pump and crankcase.
Disassembly and Repair of Pump Housing
Steps for disassembling and repairing the oil pump housing.
Fuel System
Construction and Operation of Carburetor
Explains the diaphragm carburetor's fuel pump and body construction and function.
Operation of Fuel Pump
Details how crankcase pressure actuates the fuel pump diaphragm and valves.
Operation of Carburetor
Describes the metering diaphragm's role in controlling fuel supply via the needle valve.
Troubleshooting Chart
Lists common carburetor faults, causes, and remedies.
Leakage Test (Pressure Test) on Carburetor
Method for testing carburetor airtightness using a pressure tester.
Disassembly of Carburetor
Instructions for removing the carburetor from the machine.
Repair of Carburetor
Detailed steps for disassembling and repairing carburetor components.
Carburetor Adjustment
Procedures for adjusting carburetor settings for optimal performance.
Notes for Fine Adjustment of Carburetor
Guidance on adjusting H, L, and idle speed screws for engine operation.
Fuel Line
Explains the fuel line's function and troubleshooting issues like blocked felt bars.
Tank Vent
Describes the tank vent's construction and maintenance for proper fuel supply.
Air Filter and Choke Valve
Details the air filter's function and how to check/replace the choke valve.

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