500i vs 661 Chainsaws: Which Excels in Wood Processing? (7 Pro Tips)

500i vs 661 Chainsaws: Which Excels in Wood Processing? (7 Pro Tips)

Let’s face it, the scent of freshly cut wood, the rhythmic roar of a chainsaw, and the satisfaction of a neatly stacked woodpile – it’s a feeling that’s hard to beat. For many, it’s more than just a chore; it’s a passion, a connection to nature, and a way to provide for ourselves and our families. But to truly excel in wood processing, you need the right tools.

I’ve spent countless hours in the woods, from the crisp, frosty mornings of the Appalachian Mountains to the humid, dense forests of the Pacific Northwest. I’ve felled trees, bucked logs, and split cords of wood with a variety of chainsaws, and I’ve learned firsthand what makes a chainsaw a true workhorse. In this article, I’m going to share my experiences and insights, comparing the Stihl MS 500i and the MS 661, and giving you 7 pro tips to help you make the right choice for your wood processing needs.

Understanding the Wood Processing Landscape

Wood processing is a broad term encompassing everything from felling trees to splitting firewood. It’s a critical part of many industries, from logging and construction to home heating and DIY projects. Understanding the core elements of wood processing will help you appreciate the nuances of chainsaw selection.

• Felling: Safely cutting down trees. This requires power, precision, and a solid understanding of tree lean and environmental factors.
• Limbing: Removing branches from a felled tree. This often involves working in awkward positions and requires a chainsaw that is maneuverable and well-balanced.
• Bucking: Cutting logs into shorter, manageable lengths. This is where power and cutting speed are essential for efficiency.
• Splitting: Dividing logs into smaller pieces for firewood. While chainsaws can assist in this process by creating starting points, splitting is typically done with axes, mauls, or hydraulic splitters.
• Milling: Converting logs into lumber. This requires specialized equipment like chainsaw mills or bandsaw mills, but chainsaws play a crucial role in preparing logs for milling.

Each of these steps demands specific chainsaw characteristics. A chainsaw that excels at felling might be cumbersome for limbing, and vice versa. Therefore, understanding your primary wood processing tasks is crucial for selecting the right tool.

Introducing the Contenders: Stihl MS 500i and MS 661

Let’s get down to brass tacks. The Stihl MS 500i and the MS 661 are both professional-grade chainsaws designed for demanding tasks. However, they have distinct features and strengths that make them suitable for different applications.

Stihl MS 500i:

• Engine: 79.2 cc, fuel-injected 2-MIX engine
• Power Output: 6.7 hp (5.0 kW)
• Weight: 13.9 lbs (6.3 kg) powerhead only
• Key Features: Electronic fuel injection (EFI), lightweight design, rapid acceleration
• Ideal For: Felling, limbing, bucking, and applications where power-to-weight ratio is critical.

Stihl MS 661:

• Engine: 91.1 cc, 2-MIX engine
• Power Output: 7.37 hp (5.5 kW)
• Weight: 16.3 lbs (7.4 kg) powerhead only
• Key Features: High torque, robust construction, decompression valve for easier starting
• Ideal For: Felling large trees, bucking oversized logs, and demanding applications requiring maximum power.

Pro Tip #1: Power vs. Weight – Finding the Sweet Spot

The most significant difference between these two chainsaws is the balance between power and weight. The MS 500i boasts an impressive power-to-weight ratio thanks to its lighter design and fuel-injected engine. This translates to less fatigue during extended use, faster acceleration, and improved maneuverability.

The MS 661, on the other hand, prioritizes raw power. Its larger engine delivers higher torque, allowing it to muscle through dense hardwoods and oversized logs with ease. However, this comes at the cost of increased weight, which can be a factor for all-day use.

My Experience: I remember one project in particular where I was clearing a heavily wooded lot filled with a mix of oak, maple, and hickory. I started with the MS 661, and while it effortlessly sliced through the larger oak trees, I quickly felt the strain during limbing and bucking smaller diameter trees. Switching to the MS 500i was a game-changer. The lighter weight and quicker acceleration allowed me to work faster and with less fatigue, especially when dealing with the more manageable maple and hickory.

Data Point: Studies have shown that reducing chainsaw weight by just 1 kg (2.2 lbs) can decrease operator fatigue by up to 15% over an 8-hour workday.

Actionable Takeaway: Consider the types of wood you’ll be processing most frequently. If you’re primarily dealing with large hardwoods, the MS 661’s raw power might be worth the extra weight. However, if you’re working with a mix of wood types or prioritizing maneuverability, the MS 500i’s power-to-weight ratio will be a significant advantage.

Pro Tip #2: EFI vs. Carburetor – The Fuel Injection Advantage

The Stihl MS 500i features an electronic fuel injection (EFI) system, a significant upgrade compared to the MS 661’s carburetor. This EFI system offers several advantages:

• Consistent Performance: EFI automatically adjusts the fuel mixture based on engine load, temperature, and altitude, ensuring optimal performance in all conditions.
• Easier Starting: EFI eliminates the need for manual choke adjustments, making starting easier, especially in cold weather.
• Improved Fuel Efficiency: EFI delivers fuel more precisely, resulting in better fuel economy and reduced emissions.

My Experience: I’ve always been impressed with the MS 500i’s starting reliability. Even after sitting idle for weeks, it fires up with minimal effort. The MS 661, while a reliable saw, sometimes requires a bit more coaxing, especially in colder temperatures.

Data Point: Independent tests have shown that EFI systems can improve fuel efficiency by up to 10% compared to carburetors in chainsaws.

Actionable Takeaway: If you value consistent performance, easy starting, and improved fuel efficiency, the MS 500i’s EFI system is a major selling point.

Pro Tip #3: Bar Length and Chain Selection – Matching the Tool to the Task

The bar length and chain type you choose can significantly impact your chainsaw’s performance and efficiency. Both the MS 500i and MS 661 can accommodate a range of bar lengths, but it’s essential to choose the right size for your specific needs.

• Shorter Bars (16-20 inches): Ideal for limbing, bucking smaller diameter trees, and general-purpose use. Offer improved maneuverability and reduced weight.
• Longer Bars (25-36 inches): Best suited for felling large trees and bucking oversized logs. Provide increased reach and cutting capacity.

Chain type also plays a crucial role.

• Full Chisel Chains: Offer the fastest cutting speed but require more skill to maintain and are more prone to kickback.
• Semi-Chisel Chains: More forgiving than full chisel chains, easier to sharpen, and better suited for dirty or abrasive wood.
• Low-Kickback Chains: Designed to reduce the risk of kickback, making them ideal for beginners or users who prioritize safety.

My Experience: I typically use a 20-inch bar on my MS 500i for limbing and bucking smaller firewood logs. The shorter bar makes the saw incredibly nimble and easy to control. When felling larger trees with the MS 661, I switch to a 28-inch bar to provide the necessary reach and cutting capacity.

Data Point: Studies have shown that using the correct chain type for the wood being cut can improve cutting speed by up to 20%.

Actionable Takeaway: Choose a bar length appropriate for the size of the trees you’ll be felling and bucking. Consider using a shorter bar for limbing and general-purpose use. Select a chain type that matches your skill level and the type of wood you’ll be cutting.

Pro Tip #4: Ergonomics and Comfort – Minimizing Fatigue

Wood processing can be physically demanding, so ergonomics and comfort are crucial considerations. Both the MS 500i and MS 661 are designed with user comfort in mind, but they have subtle differences.

• Vibration Dampening: Both chainsaws feature excellent vibration dampening systems, which reduce fatigue and improve control.
• Handle Design: The MS 500i has a slightly more compact handle design, which some users find more comfortable for extended use.
• Weight Distribution: The MS 500i’s lighter weight and balanced design make it easier to maneuver and control, especially during limbing and overhead work.

My Experience: I’ve noticed that after a full day of cutting with the MS 661, my arms and back feel significantly more fatigued than when using the MS 500i. The MS 500i’s lighter weight and better balance make a noticeable difference in reducing strain.

Data Point: Studies have shown that reducing vibration in power tools can decrease the risk of developing hand-arm vibration syndrome (HAVS) by up to 50%.

Actionable Takeaway: Consider your physical strength and endurance when choosing between these two chainsaws. If you’re prone to fatigue or have existing joint problems, the MS 500i’s lighter weight and better ergonomics might be a better choice.

Pro Tip #5: Maintenance and Reliability – Keeping Your Saw Running Smoothly

Proper maintenance is essential for ensuring the longevity and reliability of your chainsaw. Both the MS 500i and MS 661 are built to withstand demanding conditions, but they require regular maintenance to perform optimally.

• Air Filter Cleaning: Regularly clean the air filter to prevent engine damage and maintain performance.
• Chain Sharpening: Keep the chain sharp for efficient cutting and reduced kickback.
• Bar and Chain Lubrication: Ensure proper lubrication to prevent wear and tear on the bar and chain.
• Fuel Mixture: Use the correct fuel mixture (typically 50:1) to prevent engine damage.

My Experience: I’ve found that both the MS 500i and MS 661 are relatively easy to maintain. However, the MS 500i’s EFI system eliminates the need for carburetor adjustments, simplifying maintenance.

Data Point: Studies have shown that regular chainsaw maintenance can extend the lifespan of the saw by up to 30%.

Actionable Takeaway: Develop a regular maintenance schedule for your chainsaw. Clean the air filter, sharpen the chain, lubricate the bar and chain, and use the correct fuel mixture. Consider investing in a chainsaw maintenance kit to make the process easier.

Pro Tip #6: Safety First – Protecting Yourself in the Woods

Safety should always be your top priority when operating a chainsaw. Wear appropriate personal protective equipment (PPE) and follow safe operating procedures to minimize the risk of injury.

• Personal Protective Equipment (PPE):
  • Chainsaw Chaps: Protect your legs from accidental cuts.
  • Eye Protection: Protect your eyes from flying debris.
  • Hearing Protection: Protect your ears from loud chainsaw noise.
  • Gloves: Provide a secure grip and protect your hands.
  • Steel-Toed Boots: Protect your feet from falling logs and sharp objects.
  • Helmet: Protect your head from falling branches.
• Safe Operating Procedures:
  • Maintain a Safe Distance: Keep bystanders at least twice the height of the tree you’re felling.
  • Plan Your Escape Route: Before felling a tree, plan a clear escape route in case the tree falls unexpectedly.
  • Be Aware of Your Surroundings: Watch out for obstacles, power lines, and other hazards.
  • Use Proper Felling Techniques: Use proper felling techniques to control the direction of the falling tree.
  • Never Cut Above Shoulder Height: Cutting above shoulder height increases the risk of losing control of the chainsaw.
  • Take Breaks: Avoid fatigue by taking regular breaks.

My Experience: I’ve had a few close calls over the years, which have reinforced the importance of safety. One time, a branch snapped unexpectedly while I was limbing a tree, and I barely managed to avoid being hit. Wearing proper PPE and following safe operating procedures can make the difference between a near miss and a serious injury.

Data Point: Studies have shown that wearing chainsaw chaps can reduce the severity of leg injuries by up to 80%.

Actionable Takeaway: Always wear appropriate PPE when operating a chainsaw. Familiarize yourself with safe operating procedures and follow them diligently. Take a chainsaw safety course to learn proper techniques and avoid common mistakes.

Pro Tip #7: Cost Considerations – Balancing Performance and Budget

The Stihl MS 500i and MS 661 are both premium chainsaws with a corresponding price tag. Consider your budget and the frequency with which you’ll be using the chainsaw when making your decision.

• Initial Cost: The MS 500i typically has a slightly higher initial cost due to its advanced EFI system.
• Operating Costs: The MS 500i’s improved fuel efficiency can result in lower operating costs over time.
• Maintenance Costs: Both chainsaws require regular maintenance, but the MS 500i’s EFI system eliminates the need for carburetor adjustments, potentially reducing maintenance costs.

My Experience: I’ve found that the MS 500i’s fuel efficiency helps offset its higher initial cost over the long run. The reduced fuel consumption and easier starting make it a more cost-effective option for frequent use.

Data Point: Over a 5-year period, the MS 500i’s improved fuel efficiency can save you up to $200 in fuel costs compared to the MS 661.

Actionable Takeaway: Evaluate your budget and the frequency with which you’ll be using the chainsaw. If you’re a professional logger or firewood producer who uses a chainsaw daily, the MS 500i’s fuel efficiency and reduced maintenance costs might make it a more cost-effective option in the long run. However, if you’re an occasional user on a tight budget, the MS 661 might be a more suitable choice.

The Verdict: Which Chainsaw Excels in Wood Processing?

So, which chainsaw excels in wood processing? The answer, as with many things, is it depends.

• Choose the Stihl MS 500i if:
  • You prioritize power-to-weight ratio and maneuverability.
  • You value consistent performance and easy starting.
  • You work with a mix of wood types and sizes.
  • You appreciate advanced technology like electronic fuel injection.
  • You’re willing to invest in a premium chainsaw for long-term cost savings.
• Choose the Stihl MS 661 if:
  • You primarily fell large trees and buck oversized logs.
  • You need maximum power for demanding applications.
  • You’re comfortable with a heavier chainsaw.
  • You prefer a simpler carburetor system.
  • You’re on a tighter budget.

Ultimately, the best chainsaw for you is the one that best meets your specific needs and preferences. Take the time to research your options, consider your budget, and try out both chainsaws if possible before making a decision.

Final Thoughts:

Whether you choose the Stihl MS 500i or the MS 661, remember that a chainsaw is a powerful tool that demands respect. Prioritize safety, maintain your equipment properly, and always be aware of your surroundings. With the right chainsaw and the right knowledge, you can tackle any wood processing task with confidence and efficiency. Happy cutting!

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