How to Change Sprocket on Stihl Pole Saw: A Step-by-Step Guide for Proper Maintenance

If you own a Stihl pole saw, you know how important it is to keep it in good condition. Regular maintenance is the key to ensuring your pole saw lasts a long time and performs at its best. Part of that maintenance is changing the sprocket.

It may sound like a daunting task, but it’s actually quite simple if you know what you’re doing. In this blog post, we’ll guide you through the process of changing the sprocket on a Stihl pole saw, step by step. So grab your tools and let’s get started!

Step 1: Prepare the saw

So you’re ready to tackle the task of changing the sprocket on your Stihl pole saw? Great! The first step is to prepare the saw. Start by ensuring that the saw is turned off and disconnected from any power sources. Next, remove the bar and chain from the saw.

You can do this by loosening the nuts holding them in place, and then sliding them off of the saw. Once you’ve removed the bar and chain, you should be able to easily access the sprocket. Now is a good time to clean the saw and inspect the sprocket for any damage or wear.

If it looks worn down or damaged, it may need to be replaced. With the saw prepped and the sprocket inspected, you’re ready to move on to the next step in the process.

Disconnect the spark plug and loosen the bar nuts.

When it comes to using a chainsaw, proper preparation is key to ensuring safety and efficiency. Step one of the process involves disconnecting the spark plug and loosening the bar nuts. This step may seem small, but it is crucial to the overall process.

Disconnecting the spark plug ensures that the chainsaw won’t accidentally start while you are working on it, while loosening the bar nuts allows you to adjust the tension on the guide bar and chain. It is essential to make sure that the chain is tensioned correctly to avoid any potential accidents. By following step one, you will be setting yourself up for success in the following steps of preparing your chainsaw.

Remember, safety should always come first when using power tools, and taking the time to properly prepare your chainsaw is a must.

how to change sprocket on stihl pole saw

Remove the saw’s bar and chain.

Before starting any maintenance work on your chainsaw, it’s essential to prepare it appropriately. The first step is to remove the saw’s bar and chain; this helps to make the saw’s powerhead easier to handle. Once you’ve removed the bar and chain, you can thoroughly check and clean them.

By inspecting the chainsaw’s bar, you can determine whether there are any damages or bulges that could cause the chainsaw to be unsafe to use. Cleaning the chain will remove any debris that may have accumulated, ensuring it remains sharp and efficient. While removing the chainsaw’s bar and chain may seem like a simple task, it’s crucial to do it correctly so that they’re easy to reinstall when you’ve finished servicing your chainsaw.

With the right knowledge and tools at hand, it’s easy to complete this task.

Locate the clutch cover and remove it.

To begin the process of working on your chainsaw’s clutch system, you will need to prepare the saw by deactivating the engine and ensuring it has cooled down. Once the saw has been turned off and allowed to cool, you can begin to locate the clutch cover which is typically found on the left-hand side of the saw. The clutch cover is a protective covering that houses the chainsaw’s clutch mechanism.

Removing the clutch cover will give you access to the clutch assembly and sprocket. To remove the clutch cover, you may need to use a wrench or screwdriver to loosen and remove the bolts holding it in place. Once removed, you will have a clear view of the clutch mechanism and the sprocket.

This step is an essential part of maintaining and repairing your chainsaw, ensuring that it runs smoothly and effectively. So, get ready to roll up your sleeves and prepare to work on your chainsaw’s clutch system!

Step 2: Remove the old sprocket

Now that you’ve got your new sprocket in hand, it’s time to remove the old one. First, make sure your saw is completely powered off and the chain brake is engaged. Now, locate the bolts holding the clutch cover in place and remove them using a socket wrench.

With the cover removed, you should see the clutch and sprocket assembly. To remove the sprocket itself, you’ll need a special tool called a clutch removal tool. You can either purchase one or rent it from a local tool rental store.

Once you have the tool, insert it into the clutch and turn it counterclockwise until the clutch and sprocket come loose. At this point, you should be able to remove the sprocket from the shaft. If you’re having trouble, give it a few taps with a rubber mallet or apply some penetrating oil to help loosen it up.

Now that the old sprocket is removed, you’re ready to install the new one!

Use a socket wrench to loosen the sprocket’s retaining nut.

To remove the old sprocket, you must start by using a socket wrench to loosen the sprocket’s retaining nut. This step is crucial, as the retaining nut is what holds the sprocket in place and prevents it from coming off the axle. Using a socket wrench gives you more leverage and makes loosening the nut much easier.

Make sure to turn the wrench counterclockwise, or to the left, to unscrew the nut. Once the nut is loose, you can slide the sprocket off the axle. Be careful not to lose any small parts or washers that may be attached to the sprocket or the axle.

Removing the sprocket may require some force, so be prepared to use a little elbow grease. Remember, if the sprocket is damaged or worn out, it’s essential to replace it with a new one to ensure your bike runs smoothly and safely. By following these steps and using a socket wrench, you can quickly and easily remove your old sprocket and replace it with a new one.

Pull the sprocket off the saw’s crankshaft.

When it comes to replacing your chainsaw’s sprocket, the second step is to remove the old one. This might sound simple, but it can be a bit tricky if you’re not familiar with the process. To get started, you’ll want to pull the sprocket off the saw’s crankshaft.

This can be done using a specialized tool called a sprocket puller, which you can purchase at most hardware stores. Alternatively, you can use a regular gear puller if you don’t have access to a sprocket puller. Just be sure to follow the manufacturer’s instructions carefully to avoid damaging the crankshaft or other parts of your chainsaw.

Once the old sprocket is off, you can move on to the next steps in the replacement process, such as cleaning the area and installing the new sprocket. Keeping your chainsaw’s sprocket in good condition is key to maintaining the saw’s performance and safety, so don’t hesitate to take action if you notice any signs of wear or damage.

Remove the needle bearing from the old sprocket.

Removing the old sprocket is a crucial step in replacing it with a new one. Once you’ve removed the sprocket from the shaft, the next step is to remove the needle bearing. The needle bearing is a small component that can be easily overlooked, but it’s important to remove it before installing the new sprocket.

To remove the needle bearing, you will need a puller tool designed for this purpose. The puller tool will fit over the shaft and pull the needle bearing out of the old sprocket. Be sure to keep the needle bearing in a safe place, as you will need it for installing the new sprocket.

Once you’ve removed the needle bearing, you can discard the old sprocket and move on to installing the new one. Overall, removing the old sprocket and needle bearing is a straightforward task that requires a bit of attention to detail, but once completed, it will make room for the new sprocket and ensure a smooth operation of your machine.

Step 3: Install the new sprocket

Now that you have removed the old sprocket, it’s time to install the new one on your Stihl pole saw. Before you start, make sure the new sprocket you have purchased fits your saw model. Once you have confirmed this, take the new sprocket and slide it onto the saw’s clutch drum.

Ensure it is secured firmly onto the groove of the clutch drum and aligned properly with the chainsaw chain. Next, you can snap the sprocket cover back onto the saw. Make sure the cover is in place and secured tightly with the screws.

It’s that easy! You have successfully changed the sprocket on your Stihl pole saw, and it’s now ready to use. Remember to inspect the new sprocket periodically and replace it when necessary to ensure the safety and efficiency of your saw.

Insert the needle bearing into the new sprocket.

When installing a new sprocket, it’s important to ensure that everything is properly aligned for your bike’s best performance. The third step to installing a new sprocket is to insert the needle bearing into the new sprocket. The needle bearing is an important part of your bike’s transmission, and it’s crucial that it is properly inserted.

To start, make sure your hands are clean and dry. Carefully pick up the needle bearing, and clean it with a cloth if necessary. Then, find the hole in the center of the new sprocket and gently insert the needle bearing.

Be sure to press it all the way in until it is fully seated. Once you’ve securely installed the needle bearing, you can move on to the next steps of the installation process. With careful attention to detail and proper installation techniques, your new sprocket will provide smooth and reliable performance for countless rides to come.

Align the sprocket with the crankshaft and slide it into place.

When it comes to installing a new sprocket on your bike, it’s important to take your time and do it properly. To start, you need to align the sprocket with the crankshaft before sliding it into place. This step is crucial because if the sprocket isn’t aligned correctly, it can cause your bike to malfunction, leading to potentially dangerous situations.

Once you’ve ensured that the sprocket is in the right position, carefully slide it onto the crankshaft. You may need to give it a gentle tap to make sure it’s fully seated. Take your time when performing this step, as rushing can lead to mistakes that could cost you time and money in the long run.

By being careful and methodical, you can ensure that your new sprocket is properly installed and ready to go.

Tighten the sprocket’s retaining nut.

After removing the old sprocket, it’s time to install the new one. Before attaching the new sprocket, make sure to clean the snap ring groove to avoid any debris or dirt that can affect its performance. Then, place the sprocket in position and align it with the hub splines.

It should slide onto the hub easily but make sure it’s properly seated. Tighten the sprocket’s retaining nut with a torque wrench according to the manufacturer’s specifications. Be sure not to over-tighten, as it can damage the sprocket, causing it to wear out faster.

Once the nut is tightened, install the snap ring and double-check that the sprocket is correctly seated and secure. This step is crucial as it ensures that the sprocket is not moving and that the bike’s chain is functioning correctly. With these steps, you can install a new sprocket seamlessly, and your bike will be ready for your next ride.

Step 4: Reassemble the saw

Now that you have successfully replaced the sprocket on your Stihl pole saw, it’s time to put everything back together. Start by placing the clutch assembly back onto the saw and securing it with the retaining clip. Next, thread the starter rope back through the housing and reattach the handle.

Take your new sprocket and slide it over the clutch drum, ensuring that it fits snugly. Then, reattach the guide bar and chain to the saw, making sure everything is aligned properly. Finally, add bar and chain oil to the reservoir and test out your saw to make sure everything is running smoothly.

With this simple process, you can get your Stihl pole saw back up and running in no time.

Replace the clutch cover.

If you’re wondering how to reassemble your chainsaw, step 4 is all about replacing the clutch cover. This is an essential part of the process as the clutch cover protects the saw’s chain and bar, ensuring they operate smoothly and efficiently. To begin, carefully align the clutch cover back onto the saw, making sure it locks into place.

You’ll then need to reattach the screws, ensuring that they are tightened securely enough to hold the cover in place, but not so tight that they strip the threads. Pay attention to the torque on the screws as too much force can cause damage to the saw. Once the cover is securely in place, it’s time to attach the chain brake and tighten the brake band.

Remember to always use the appropriate safety gear when working with power tools, including gloves and safety glasses. With your clutch cover now in place, your saw is ready to be tested and put back into use!

Replace the bar and chain.

Now that you’ve replaced the bar and chain on your chainsaw, it’s time to reassemble the saw. First, clean any debris or sawdust from the chainsaw before reattaching the bar and chain. Make sure the bar is securely in place before reinserting the chain.

Once the chain is in place, adjust the tension so that it’s tight but not too tight. It should move freely around the bar without sagging. Finally, tighten the bar nuts to hold everything in place.

Your chainsaw should now be ready to use again. With a new chain and bar, it’ll be like using a brand new saw! Remember to take care of your tools, and they’ll take care of you in the long run.

Tighten the bar nuts and reattach the spark plug.

After completing the previous steps of cleaning and replacing the chainsaw parts, it’s time to reassemble the saw. You must first tighten the bar nuts, which you can do by hand before using a wrench for extra tightness. Make sure to reattach the spark plug, but don’t forget to gap it first.

Having a gap that’s too large could cause starting problems, and a gap that’s too small could lead to engine failure. With these two steps completed, you’re well on your way to successfully reassembling your chainsaw. It’s important to note that keeping your chainsaw properly assembled will prolong its lifespan and ensure its safe operation.

Don’t cut corners when it comes to assembly – put the time and effort in, and your chainsaw will function smoothly for years to come.

Tips and Warnings

Changing the sprocket on your Stihl pole saw can be a great way to keep it working at its best. However, it’s important to take the necessary precautions before diving into this job. Firstly, always ensure your saw is switched off and unplugged before starting any maintenance.

This will minimize the risk of injury or accidental damage. Additionally, remember to wear protective gear such as safety glasses, hearing protection, and gloves. Before beginning, it’s worth noting that this job can be complex and requires some level of technical expertise.

If you’re unsure about your ability to complete the job safely or effectively, it may be best to seek the help of a professional. Overall, with the right approach, changing the sprocket on your Stihl pole saw can help you get the most out of your tool for years to come.

Never attempt to change the sprocket without disconnecting the spark plug first.

When it comes to changing the sprocket on your bike, it’s important to take certain precautions to avoid injury or damage to your vehicle. One essential tip to keep in mind is to always disconnect the spark plug before attempting to change your sprocket. This will prevent the engine from accidentally kicking over while you’re working and potentially causing harm to yourself or others.

Additionally, when working on your bike, be sure to wear protective gear such as gloves and safety glasses to avoid any cuts or debris in your eyes. It’s also important to use the appropriate tools for the job and to have someone nearby who can help in case of an emergency. Following these tips can ensure a safer and smoother experience when changing your sprocket.

Don’t forget to always put safety first!

Always use the correct tools and safety equipment.

When it comes to DIY projects, it’s important to always use the correct tools and safety equipment. Not only does this ensure the job is done correctly, but it also protects you from potential injury. Before starting any project, make sure you have all the necessary tools and equipment on hand.

This could include things like safety glasses, gloves, earplugs, and a hard hat. It’s also important to make sure you’re using the correct tool for the job. Using a tool that isn’t meant for the task at hand can not only be dangerous but can also damage your project.

Always take the time to read the manual and follow the instructions carefully. In addition, never remove safety features from your tools – they’re there for a reason! By prioritizing safety and using the correct tools, you can ensure a successful and injury-free DIY project.

If you’re unsure about any aspect of the sprocket replacement process, seek professional assistance.

If you’re considering replacing your sprocket, it’s important to know that the process can be complex and requires some technical know-how. Before starting, make sure that you have all the necessary tools and parts, and that you understand the specific steps required for your particular bike and sprocket setup. If you’re unsure about any aspect of the process, seeking professional assistance is always a good idea.

Attempting to replace your sprocket without proper knowledge or experience can result in costly mistakes, such as damaging your bike or putting your own safety at risk. That being said, if you feel confident in your abilities and have thoroughly researched the process, replacing your own sprocket can be a rewarding and cost-effective option. Just make sure to take proper precautions and follow all necessary safety guidelines.


In conclusion, changing the sprocket on your Stihl pole saw is a relatively simple task, as long as you have the right tools and follow a few key steps. With a little bit of patience and attention to detail, you’ll have your saw up and running again in no time. So whether you’re a professional tree trimmer or just a DIY enthusiast, don’t be intimidated by the process – with a little bit of effort and know-how, you’ll soon be back to pruning your vegetation with ease.

Happy sawing!”


What is a sprocket and why does it need to be changed on a Stihl pole saw?
A sprocket is a wheel with teeth that helps rotate the chain on a pole saw. It may need to be changed if it becomes worn or damaged, which can affect the saw’s efficiency and safety.

What tools do I need to change the sprocket on my Stihl pole saw?
You will need a socket wrench, a hammer, a punch, and a new sprocket that is compatible with your pole saw.

How do I remove the old sprocket from my Stihl pole saw?
First, remove the chain and bar from the saw. Then, use the socket wrench to remove the bolt holding the sprocket in place. Use the punch and hammer to tap the sprocket off if it is stuck.

How do I install the new sprocket on my Stihl pole saw?
Place the new sprocket on the saw, making sure it lines up with the shaft. Use the socket wrench to tighten the bolt securely. Replace the bar and chain back onto the saw.

Can I change the sprocket on my Stihl pole saw myself, or do I need a professional?
If you have the tools and experience working with power tools, you can change the sprocket on your Stihl pole saw yourself. However, if you are not confident in your abilities, it is recommended to have a professional do the job for safety reasons.

How often should I change the sprocket on my Stihl pole saw?
The frequency of sprocket changes depends on how often you use your saw and the type of work you do with it. It is recommended to inspect the sprocket regularly for wear and have it changed if necessary.

Where can I purchase a replacement sprocket for my Stihl pole saw?
You can purchase a replacement sprocket from a Stihl dealer or from an online retailer that specializes in outdoor power equipment parts. Make sure to get the correct sprocket that matches the model and size of your pole saw.

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