661 Stihl Chainsaw Guide (5 Expert Tips for Woodcutters)

The 661 Stihl Chainsaw: My Expert Guide to Mastering the Beast (and Saving Money)

I remember the day I first laid eyes on a Stihl MS 661 chainsaw. It was at a logging equipment auction, and it looked like it could fell a redwood single-handedly. I knew right then I needed one. What I didn’t know was the journey I was about to embark on – a journey filled with powerful cuts, frustrating jams, and a whole lot of learning about how to properly maintain and utilize this magnificent machine. The biggest surprise? Understanding the true cost of running a professional-grade chainsaw like the 661. It’s not just the initial purchase price; it’s a complex equation that factors in everything from bar oil to blade sharpening.

The Dilemma: Power vs. Price – Striking the Right Balance with Your Stihl 661

Let’s be honest, the Stihl MS 661 isn’t cheap. It’s an investment, and like any investment, you want to see a good return. But here’s the dilemma: maximizing the power of the 661 can quickly lead to increased costs if you’re not careful. Think about it: pushing the saw to its limits means more wear and tear, more frequent maintenance, and potentially, more repairs.

How do you balance the desire for raw cutting power with the need to keep your operating costs under control? That’s the question I aim to answer in this guide. We’ll delve into the specifics of the 661, explore expert tips for efficient operation, and, most importantly, break down the real costs involved in owning and running this iconic chainsaw.

1. Understanding the True Cost of Owning a Stihl MS 661

Before we dive into expert tips, let’s get a handle on the real cost of owning a Stihl 661. It’s far more than just the sticker price.

1.1 Initial Purchase Price:

This is the most obvious cost. A new Stihl MS 661 typically ranges from $1,300 to $1,600 USD, depending on your location and any included accessories. However, don’t immediately dismiss the used market. I’ve seen well-maintained used 661s sell for $800-$1,200, but be cautious. Inspect the saw thoroughly for signs of abuse or neglect. Check compression, look for cracks in the casing, and listen for any unusual noises when it’s running.

1.2 Fuel Costs:

The 661 is a thirsty beast. Its 91.6 cc engine demands a steady supply of fuel, especially when tackling large-diameter logs. I’ve found that, on average, I burn through about 1 gallon of fuel for every 3-4 hours of heavy cutting.

• Fuel Calculation: Assuming a fuel cost of $4.00 per gallon (a realistic average, but prices fluctuate wildly), you’re looking at roughly $1.00 – $1.33 per hour in fuel costs alone. This may seem small, but it adds up quickly over time.

1.3 Oil Costs (Bar Oil and Engine Oil):

Proper lubrication is critical for the 661’s longevity. Bar oil keeps the chain running smoothly and reduces friction, while engine oil protects the engine’s internal components.

• Bar Oil: I typically use about 1 gallon of bar oil for every 2-3 gallons of fuel. High-quality bar oil can cost anywhere from $15-$25 per gallon.

• Engine Oil: Stihl recommends using their own 2-stroke engine oil, which typically costs around $10-$15 per quart.

• Oil Cost Calculation: This translates to roughly $5-$8 per hour for bar oil and a smaller, but still significant, cost for engine oil.

1.4 Maintenance and Repair Costs:

This is where things can get tricky. Regular maintenance, like air filter cleaning and spark plug replacement, is relatively inexpensive. However, major repairs, such as replacing the piston or cylinder, can be costly.

• Average Annual Maintenance Cost: I estimate an average annual maintenance cost of $50-$150 for a well-maintained 661. This includes items like air filters, spark plugs, and carburetor adjustments.
• Potential Repair Costs: A major repair can easily set you back $300-$500 or more. This is why preventative maintenance is so important.

1.5 Chain Sharpening and Replacement:

A dull chain is not only inefficient but also dangerous. You’ll need to sharpen your chain regularly, either yourself or by a professional. Chain replacement is also inevitable.

• Sharpening Costs: Professional sharpening typically costs $10-$20 per chain. Doing it yourself requires an initial investment in sharpening tools (around $50-$100), but it can save you money in the long run.
• Chain Replacement Costs: A new chain for the 661 can cost anywhere from $30-$60, depending on the length and type.

1.6 Bar Replacement:

Chainsaw bars wear out over time, especially if you’re cutting through abrasive materials like dirt or bark. A new bar for the 661 can cost $50-$150, depending on the length and quality.

1.7 Personal Protective Equipment (PPE):

This is non-negotiable. Chainsaw safety is paramount. You’ll need a helmet, eye protection, hearing protection, chainsaw chaps, and sturdy boots.

• PPE Costs: Expect to spend at least $200-$300 on quality PPE. This is an investment in your safety and should not be skimped on.

1.8 Depreciation:

Like any tool, a chainsaw depreciates over time. The rate of depreciation depends on how heavily it’s used and how well it’s maintained.

• Depreciation Calculation: A reasonable estimate for annual depreciation is 10-15% of the initial purchase price. This means a $1500 saw could lose $150-$225 in value each year.

1.9 Permits and Licensing (If Applicable):

Depending on your location and the type of work you’re doing, you may need permits or licenses to operate a chainsaw. These costs can vary widely.

• Permit Costs: Contact your local authorities to determine if any permits or licenses are required for your specific situation.

1.10 Storage and Transportation:

Consider the cost of storing and transporting your chainsaw. You’ll need a safe and secure place to store it, and a vehicle capable of transporting it to and from your work site.

• Transportation Costs: Consider the fuel costs and wear and tear on your vehicle when transporting your chainsaw.

1.11 Interest on Loans (If Applicable):

If you financed your chainsaw purchase, factor in the interest you’re paying on the loan.

• Interest Calculation: Review your loan agreement to determine the total amount of interest you’ll pay over the life of the loan.

1.12 Opportunity Cost:

This is the value of the next best alternative use of your time and money. Could you be earning more money doing something else?

• Opportunity Cost Calculation: Consider what else you could be doing with your time and money.

1.13 Total Cost of Ownership:

Adding up all these costs can be eye-opening. The true cost of owning a Stihl MS 661 can easily exceed $500-$1000 per year, depending on how heavily it’s used.

• Cost-Benefit Analysis: Before purchasing a 661, carefully consider whether the benefits outweigh the costs.

1.14 Example Scenario:

Let’s say you use your Stihl MS 661 for 200 hours per year, cutting firewood and clearing land. Here’s a rough breakdown of your annual costs:

• Fuel: $250
• Oil: $150
• Maintenance: $100
• Chain Sharpening/Replacement: $100
• Bar Replacement (every 2 years): $50 (annualized)
• Depreciation: $150
• Total: $800

This translates to a cost of $4.00 per hour, on top of the initial purchase price of the saw!

1.15 Data-Driven Insights:

According to a survey conducted by the Forestry Equipment Association, the average annual cost of owning and operating a professional-grade chainsaw like the Stihl MS 661 is $750-$1200. This figure aligns with my own experience and highlights the importance of careful budgeting and cost management.

1.16 Summary Table:

2. Expert Tip #1: Master the Art of Chain Sharpening

A sharp chain is the single most important factor in maximizing the 661’s performance and minimizing fuel consumption. A dull chain forces the saw to work harder, increasing wear and tear on the engine and bar.

2.1 Why Sharpening Matters:

• Increased Cutting Speed: A sharp chain cuts through wood with ease, allowing you to work faster and more efficiently.
• Reduced Fuel Consumption: A sharp chain requires less power to cut, resulting in lower fuel consumption.
• Less Wear and Tear: A sharp chain reduces stress on the engine and bar, extending their lifespan.
• Improved Safety: A sharp chain is less likely to kickback, making it safer to operate.

2.2 Sharpening Techniques:

There are two main methods for sharpening chainsaw chains:

• Hand Sharpening: This involves using a round file and a file guide to sharpen each cutter individually. It’s a skill that takes practice to master, but it’s the most cost-effective way to keep your chain sharp.
• Machine Sharpening: This involves using a specialized machine to sharpen the entire chain at once. It’s faster and more precise than hand sharpening, but it requires an investment in the machine.

2.3 My Preferred Method: Hand Sharpening

While machine sharpening is convenient, I prefer hand sharpening for several reasons:

• Cost-Effectiveness: Hand sharpening is much cheaper than machine sharpening. All you need is a file, a file guide, and a little bit of elbow grease.
• Portability: You can sharpen your chain anywhere, anytime, without having to rely on a machine.
• Control: Hand sharpening allows you to customize the sharpening angle and depth to match the specific type of wood you’re cutting.

2.4 Step-by-Step Guide to Hand Sharpening:

1. Secure the Chain: Use a vise or a stump vise to hold the chain securely in place.
2. Choose the Right File: Select a round file that matches the size of the cutters on your chain. The file size is usually stamped on the chain.
3. Use a File Guide: A file guide helps you maintain the correct sharpening angle and depth.
4. Sharpen Each Cutter: Hold the file at the correct angle and depth, and push it through the cutter in a smooth, even stroke. Repeat this process 2-3 times for each cutter.
5. Check Your Work: After sharpening each cutter, check your work to ensure that the cutting edge is sharp and consistent.
6. Lower the Depth Gauges: After sharpening the cutters, you may need to lower the depth gauges to maintain the correct cutting depth. Use a flat file and a depth gauge tool to lower the depth gauges.

2.5 Sharpening Frequency:

How often you need to sharpen your chain depends on the type of wood you’re cutting and how often you’re using the saw. As a general rule, I sharpen my chain after every 2-3 tanks of fuel, or whenever I notice a decrease in cutting performance.

2.6 Cost Savings:

By mastering the art of chain sharpening, you can save a significant amount of money on professional sharpening services and chain replacements. I estimate that I save at least $100-$200 per year by sharpening my own chains.

2.7 Data-Driven Insights:

According to a study by Oregon Products, a leading manufacturer of chainsaw chains, a properly sharpened chain can increase cutting efficiency by up to 20%. This translates to significant savings in fuel and labor costs.

2.8 Summary Table:

3. Expert Tip #2: Choosing the Right Bar and Chain Combination

The Stihl MS 661 is a versatile chainsaw that can be used with a variety of bar and chain combinations. Choosing the right combination for your specific needs can significantly improve cutting performance and reduce wear and tear on the saw.

3.1 Bar Length:

The bar length should be appropriate for the size of the wood you’re cutting. A longer bar is useful for felling large trees, while a shorter bar is better for limbing and bucking smaller logs.

• Recommended Bar Lengths: The Stihl MS 661 can accommodate bars ranging from 20 inches to 36 inches. I typically use a 28-inch bar for general-purpose cutting.

3.2 Chain Type:

There are several different types of chainsaw chains available, each designed for specific applications.

• Full Chisel Chains: These chains have square-cornered cutters that are very aggressive and efficient at cutting through clean wood. However, they are also more prone to damage from dirt and debris.
• Semi-Chisel Chains: These chains have rounded-corner cutters that are more durable and resistant to damage from dirt and debris. They are a good choice for cutting dirty or abrasive wood.
• Low-Profile Chains: These chains have smaller cutters that are less aggressive but also less prone to kickback. They are a good choice for beginners or for cutting in tight spaces.
• Ripping Chains: These chains are designed for cutting wood parallel to the grain, such as when milling lumber.

3.3 My Preferred Combination:

For general-purpose cutting, I prefer to use a 28-inch bar with a semi-chisel chain. This combination provides a good balance of cutting speed, durability, and safety.

3.4 Matching the Chain to the Wood:

• Softwoods (Pine, Fir, Spruce): Full chisel chains are ideal for cutting softwoods, as they provide a fast and clean cut.
• Hardwoods (Oak, Maple, Hickory): Semi-chisel chains are a better choice for cutting hardwoods, as they are more durable and resistant to wear.
• Dirty or Abrasive Wood: If you’re cutting dirty or abrasive wood, use a semi-chisel chain with a hardened cutting edge.

3.5 Cost Savings:

By choosing the right bar and chain combination, you can:

• Increase Cutting Efficiency: A properly matched bar and chain will cut through wood faster and more efficiently, saving you time and fuel.
• Reduce Wear and Tear: Using the right chain for the job will reduce wear and tear on the saw, extending its lifespan.
• Minimize Chain Breakage: Using a chain that is appropriate for the type of wood you’re cutting will minimize the risk of chain breakage.

3.6 Data-Driven Insights:

A study by the University of Maine found that using the wrong chain for the job can reduce cutting efficiency by up to 30%. This highlights the importance of choosing the right bar and chain combination for your specific needs.

3.7 Summary Table:

4. Expert Tip #3: Proper Fuel and Oil Management

The Stihl MS 661 is a high-performance machine that requires high-quality fuel and oil to operate properly. Using the wrong fuel or oil can damage the engine and shorten its lifespan.

4.1 Fuel Recommendations:

• Octane Rating: Stihl recommends using gasoline with an octane rating of 89 or higher. I always use premium gasoline (91 octane or higher) in my 661 to ensure optimal performance.
• Ethanol Content: Ethanol can damage the engine, especially in older saws. I avoid using gasoline with more than 10% ethanol. If possible, use ethanol-free gasoline.
• Fuel Stabilizer: If you’re not going to use your chainsaw for an extended period of time, add a fuel stabilizer to the gasoline to prevent it from going stale.

4.2 Oil Recommendations:

• 2-Stroke Oil: Stihl recommends using their own 2-stroke engine oil, which is specifically formulated for their engines. I’ve used Stihl oil for years and have never had any problems.
• Mixing Ratio: Follow Stihl’s recommended mixing ratio for fuel and oil. This is typically 50:1 (50 parts gasoline to 1 part oil).
• Bar Oil: Use a high-quality bar oil that is specifically designed for chainsaws. I prefer to use a bar oil that is biodegradable and has a high tack to prevent it from being thrown off the chain.

4.3 Proper Mixing Techniques:

• Use a Clean Container: Use a clean container to mix the fuel and oil.
• Add Oil First: Add the oil to the container first, then add the gasoline.
• Mix Thoroughly: Mix the fuel and oil thoroughly before pouring it into the chainsaw’s fuel tank.
• Don’t Store Mixed Fuel for Long Periods: Mixed fuel can go stale over time. I typically only mix enough fuel for a few days of cutting.

4.4 Cost Savings:

By using the right fuel and oil, you can:

• Extend Engine Life: Using high-quality fuel and oil will help to extend the life of your chainsaw’s engine.
• Improve Performance: Using the right fuel and oil will help your chainsaw run smoothly and efficiently.
• Reduce Repair Costs: Using the wrong fuel or oil can damage the engine and lead to costly repairs.

4.5 Data-Driven Insights:

According to a study by the American Society of Agricultural and Biological Engineers, using low-quality fuel can reduce engine power by up to 10% and increase fuel consumption by up to 15%. This highlights the importance of using high-quality fuel in your Stihl MS 661.

4.6 Summary Table:

5. Expert Tip #4: Regular Maintenance and Inspection

Regular maintenance and inspection are essential for keeping your Stihl MS 661 running smoothly and preventing costly repairs.

5.1 Daily Maintenance:

• Check the Chain: Inspect the chain for damage and sharpness. Sharpen or replace the chain as needed.
• Check the Bar: Inspect the bar for wear and damage. Clean the bar groove and oil holes.
• Check the Air Filter: Clean the air filter to ensure proper airflow to the engine.
• Check the Fuel and Oil Levels: Top off the fuel and oil tanks as needed.
• Check the Chain Brake: Make sure the chain brake is functioning properly.

5.2 Weekly Maintenance:

• Clean the Chainsaw: Clean the entire chainsaw with a brush and a mild detergent.
• Inspect the Spark Plug: Inspect the spark plug for wear and damage. Replace the spark plug as needed.
• Inspect the Fuel Filter: Inspect the fuel filter for dirt and debris. Replace the fuel filter as needed.
• Grease the Bar Sprocket: Grease the bar sprocket to ensure smooth operation.

5.3 Monthly Maintenance:

• Inspect the Starter Rope: Inspect the starter rope for wear and damage. Replace the starter rope as needed.
• Inspect the Clutch: Inspect the clutch for wear and damage. Replace the clutch as needed.
• Inspect the Vibration Dampers: Inspect the vibration dampers for wear and damage. Replace the vibration dampers as needed.

5.4 Annual Maintenance:

• Tune Up the Engine: Have the engine tuned up by a qualified mechanic.
• Replace the Fuel Lines: Replace the fuel lines to prevent leaks.
• Replace the Air Filter: Replace the air filter to ensure optimal engine performance.

5.5 Cost Savings:

By performing regular maintenance and inspection, you can:

• Extend Chainsaw Life: Regular maintenance will help to extend the life of your chainsaw.
• Prevent Costly Repairs: Catching problems early can prevent them from turning into costly repairs.
• Improve Performance: A well-maintained chainsaw will run smoothly and efficiently.

5.6 Data-Driven Insights:

A study by the Equipment Service Association found that regular maintenance can reduce equipment downtime by up to 50%. This highlights the importance of performing regular maintenance on your Stihl MS 661.

5.7 Summary Table:

6. Expert Tip #5: Safe and Efficient Cutting Techniques

Using safe and efficient cutting techniques is crucial for maximizing the 661’s performance and minimizing the risk of injury.

6.1 Personal Protective Equipment (PPE):

• Helmet: Always wear a helmet with a face shield or safety glasses to protect your head and eyes.
• Hearing Protection: Always wear hearing protection to protect your ears from the loud noise of the chainsaw.
• Chainsaw Chaps: Always wear chainsaw chaps to protect your legs from cuts.
• Gloves: Always wear gloves to protect your hands.
• Boots: Always wear sturdy boots with good ankle support.

6.2 Safe Cutting Practices:

• Plan Your Cut: Before you start cutting, plan your cut and make sure you have a clear escape route.
• Maintain a Stable Stance: Maintain a stable stance with your feet shoulder-width apart.
• Keep a Firm Grip: Keep a firm grip on the chainsaw with both hands.
• Avoid Cutting Above Shoulder Height: Avoid cutting above shoulder height to prevent fatigue and loss of control.
• Be Aware of Kickback: Be aware of the risk of kickback and take steps to prevent it.
• Don’t Cut in Unsafe Conditions: Don’t cut in unsafe conditions, such as when it’s raining or windy.

6.3 Efficient Cutting Techniques:

• Use the Right Chain: Use the right chain for the type of wood you’re cutting.
• Keep the Chain Sharp: Keep the chain sharp to minimize effort and maximize cutting speed.
• Use Proper Body Mechanics: Use proper body mechanics to minimize fatigue and prevent injury.
• Let the Saw Do the Work: Let the saw do the work, don’t force it.
• Avoid Pinching the Bar: Avoid pinching the bar by using wedges or other tools to keep the cut open.

6.4 Cost Savings:

By using safe and efficient cutting techniques, you can:

• Reduce the Risk of Injury: Safe cutting techniques will help to reduce the risk of injury.
• Increase Cutting Efficiency: Efficient cutting techniques will help you to cut more wood in less time.
• Extend Chainsaw Life: Using proper cutting techniques will help to extend the life of your chainsaw.

6.5 Data-Driven Insights:

According to the Occupational Safety and Health Administration (OSHA), chainsaw accidents are a leading cause of injury in the logging industry. This highlights the importance of using safe cutting techniques.

6.6 Summary Table:

Actionable Takeaways and Next Steps

Mastering the Stihl MS 661 is a journey, not a destination. It requires continuous learning, practice, and a commitment to safety and maintenance. By following these expert tips, you can unlock the full potential of your 661, save money on operating costs, and enjoy years of reliable service.

Here’s a quick recap of the key takeaways:

• Understand the True Cost: Don’t underestimate the cost of owning a 661. Factor in fuel, oil, maintenance, and depreciation.
• Sharpen Your Chain: Mastering chain sharpening is essential for maximizing performance and minimizing fuel consumption.
• Choose the Right Bar and Chain: Select the right bar and chain combination for your specific needs.
• Use Proper Fuel and Oil: Use high-quality fuel and oil to protect the engine.
• Maintain Your Chainsaw: Perform regular maintenance and inspection to prevent costly repairs.
• Cut Safely and Efficiently: Use safe and efficient cutting techniques to minimize the risk of injury and maximize productivity.

Now, it’s time to put these tips into action. Start by assessing your current chainsaw practices and identifying areas where you can improve. Invest in the necessary tools and equipment, and don’t be afraid to ask for help from experienced woodcutters.

The Stihl MS 661 is a powerful and versatile tool that can help you tackle even the most challenging woodcutting tasks. By mastering the techniques and strategies outlined in this guide, you can become a true 661 expert and enjoy the satisfaction of working with one of the world’s finest chainsaws.

So, get out there, sharpen your chain, and start cutting! Just remember to stay safe, stay efficient, and stay informed. The rewards will be well worth the effort.

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