Chainsaw Hard To Pull Starter Cord (Stihl MS291 Fix Tips)

Let’s talk about getting your Stihl MS291 chainsaw firing up smoothly every time. I believe the best option to address a hard-to-pull starter cord is a systematic approach: start with the simple checks, move to lubrication, and then delve into the more complex components if needed. This guide will walk you through each step, sharing some personal experiences and insights I’ve gained over years of working with chainsaws. I’ll cover everything from basic troubleshooting to more advanced repairs.

Understanding the Problem: Why Is My Starter Cord So Hard to Pull?

Before diving into solutions, it’s crucial to understand the potential reasons behind a hard-to-pull starter cord. Several factors can contribute, ranging from simple lubrication issues to more complex mechanical problems. Here’s a breakdown:

Lack of Lubrication: The recoil spring and other moving parts within the starter assembly need lubrication to function smoothly.
Excessive Resistance: The engine cylinder might be experiencing excessive resistance, making it harder to turn over.
Faulty Spark Plug: A worn or fouled spark plug can create resistance.
Damaged Starter Components: A worn recoil spring, pawls, or starter rope can hinder the starting process.
Cylinder Issues: A damaged piston or cylinder can cause significant resistance.

Phase 1: Quick Checks and Simple Solutions

Let’s start with the easiest fixes first. These are the things I check immediately when I encounter a hard-to-pull starter.

1.1 Inspect the Starter Cord and Handle

Check for Wear and Tear: Look for fraying, cuts, or knots in the starter cord. A damaged cord can bind within the starter assembly.
Examine the Handle: Ensure the handle is securely attached to the cord. A loose handle can make it difficult to get a good grip and pull effectively.
Personal Experience: I once spent an hour troubleshooting a hard-to-pull starter only to discover the cord was frayed and catching inside the housing. A quick cord replacement solved the problem.

1.2 Check the Spark Plug

Visual Inspection: Remove the spark plug and inspect it for signs of fouling (carbon buildup) or damage.
Cleaning the Spark Plug: If the spark plug is fouled, clean it with a wire brush or spark plug cleaner. You can also use a small amount of carburetor cleaner.
Spark Plug Gap: Ensure the spark plug gap is set correctly. For the Stihl MS291, the recommended gap is typically around 0.020 inches (0.5 mm). Use a spark plug gap tool to adjust if necessary.
Testing the Spark Plug: Use a spark plug tester to check if the spark plug is producing a strong spark. If not, replace the spark plug.
Tool List: Spark plug wrench, wire brush, spark plug cleaner, spark plug gap tool, spark plug tester.
Why it Matters: A faulty spark plug can create back pressure in the cylinder, making it harder to pull the starter cord.

1.3 Inspect the Air Filter

Check for Clogs: A dirty or clogged air filter restricts airflow to the engine, potentially causing resistance.
Cleaning the Air Filter: Remove the air filter and clean it with soap and water. Allow it to dry completely before reinstalling. For paper filters, consider replacing them if they are heavily soiled.
Personal Experience: I’ve seen chainsaws completely fail to start due to a severely clogged air filter. Regular cleaning is key to maintaining performance.
Tool List: Soap, water, air compressor (optional).
Frequency: I recommend cleaning the air filter every 10-20 hours of use, depending on the operating conditions.

1.4 Check the Fuel

Old Fuel: Old or stale fuel can cause starting problems. Drain the fuel tank and replace it with fresh fuel.
Fuel Mix: Ensure the fuel is properly mixed with the correct ratio of oil. Stihl recommends a 50:1 fuel-to-oil ratio for the MS291.
Fuel Filter: Check the fuel filter inside the fuel tank. A clogged fuel filter can restrict fuel flow to the carburetor. Replace the fuel filter if necessary.
Tool List: Fuel can, fresh fuel, 2-cycle oil, fuel filter removal tool.
Why it Matters: Improper fuel mixtures or old fuel can lead to poor combustion and increased resistance.

Phase 2: Lubrication and Starter Assembly Inspection

If the quick checks don’t solve the problem, it’s time to delve deeper into the starter assembly and lubrication.

2.1 Lubricate the Starter Mechanism

Access the Starter: Remove the starter assembly from the chainsaw. This usually involves removing a few screws or bolts.
Clean the Assembly: Use a brush or compressed air to remove any dirt, debris, or old grease from the starter assembly.
Lubricate Moving Parts: Apply a small amount of high-quality grease or silicone lubricant to the recoil spring, pawls, and other moving parts.
Personal Experience: I’ve found that a little lubrication can make a huge difference in the smoothness of the starter. I use a silicone-based lubricant because it doesn’t attract as much dirt and grime.
Tool List: Screwdrivers, wrenches, brush, compressed air, grease or silicone lubricant.
Frequency: I recommend lubricating the starter mechanism every 50-100 hours of use.

2.2 Inspect the Recoil Spring

Check for Damage: Examine the recoil spring for any signs of damage, such as breaks, kinks, or rust.
Test the Spring Tension: Ensure the recoil spring has adequate tension. If the spring is weak, it may not retract the starter cord properly.
Replacing the Spring: If the recoil spring is damaged or weak, replace it with a new one. This can be a bit tricky, so follow the instructions in your Stihl MS291 service manual or watch a tutorial video.
Tool List: Screwdrivers, wrenches, recoil spring replacement tool (optional).
Caution: Recoil springs can be under tension, so handle them carefully to avoid injury.

2.3 Inspect the Starter Pawls

Check for Wear: Examine the starter pawls (also known as dogs) for wear or damage. These small parts engage with the flywheel to turn the engine over.
Test the Pawl Movement: Ensure the pawls move freely and engage properly with the flywheel.
Replacing the Pawls: If the pawls are worn or damaged, replace them.
Tool List: Screwdrivers, wrenches.
Why it Matters: Worn pawls can slip and fail to engage the flywheel, making it difficult to start the chainsaw.

2.4 Inspect the Flywheel

Check for Damage: Examine the flywheel for any signs of damage, such as cracks or broken fins.
Clean the Flywheel: Clean the flywheel with a brush or compressed air to remove any dirt or debris.
Tool List: Brush, compressed air.
Why it Matters: A damaged flywheel can affect the engine’s timing and performance.

Phase 3: Engine Compression and Internal Issues

If the previous steps haven’t resolved the issue, the problem may lie within the engine itself. This requires a more in-depth inspection and potentially professional assistance.

3.1 Check Engine Compression

Compression Tester: Use a compression tester to measure the engine’s compression. The Stihl MS291 should have a compression reading of around 120-140 PSI (pounds per square inch).
Low Compression: If the compression is low, it could indicate a problem with the piston rings, cylinder, or valves.
Personal Experience: I once had a chainsaw with low compression due to worn piston rings. Replacing the piston and rings restored the engine’s compression and starting ability.
Tool List: Compression tester.
Caution: Engine compression testing requires some mechanical knowledge and skill. If you’re not comfortable performing this test, take your chainsaw to a qualified technician.

3.2 Inspect the Piston and Cylinder

Visual Inspection: If the compression is low, remove the cylinder head and inspect the piston and cylinder for signs of damage, such as scoring, scratches, or cracks.
Piston Ring Condition: Check the condition of the piston rings. They should be free to move in their grooves and not excessively worn.
Cylinder Wall Condition: Examine the cylinder walls for any signs of damage.
Tool List: Wrenches, screwdrivers, piston ring compressor (optional).
Why it Matters: Damage to the piston or cylinder can significantly reduce engine compression and make it difficult to start the chainsaw.

3.3 Check for Hydro Lock

What is Hydro Lock? Hydro lock occurs when liquid (usually fuel or oil) enters the cylinder and prevents the piston from reaching the top of its stroke.
Symptoms of Hydro Lock: A hard-to-pull starter cord is a common symptom of hydro lock.
How to Fix Hydro Lock: Remove the spark plug and pull the starter cord several times to expel the liquid from the cylinder.
Preventing Hydro Lock: Avoid over-priming the engine or storing the chainsaw with the fuel tank full.
Tool List: Spark plug wrench.

Phase 4: Carburetor Issues

Although less common, carburetor problems can sometimes contribute to a hard-to-pull starter cord.

4.1 Check the Carburetor Settings

Idle Speed: Ensure the idle speed is set correctly. If the idle speed is too low, the engine may stall easily, making it harder to start.
High and Low Speed Adjustments: Adjust the high and low speed screws on the carburetor to optimize engine performance. Refer to your Stihl MS291 owner’s manual for the recommended settings.
Tool List: Screwdriver.
Why it Matters: Improper carburetor settings can lead to poor combustion and increased resistance.

4.2 Clean the Carburetor

Remove the Carburetor: Remove the carburetor from the chainsaw.
Disassemble the Carburetor: Carefully disassemble the carburetor, taking note of the location of each part.
Clean the Carburetor Components: Clean all of the carburetor components with carburetor cleaner. Pay particular attention to the jets and passages.
Reassemble the Carburetor: Reassemble the carburetor, ensuring that all of the parts are properly installed.
Tool List: Screwdrivers, carburetor cleaner.
Caution: Carburetors are complex devices. If you’re not comfortable disassembling and cleaning a carburetor, take your chainsaw to a qualified technician.

Phase 5: Advanced Troubleshooting and Professional Help

If you’ve exhausted all of the above steps and your Stihl MS291 starter cord is still hard to pull, it’s time to consider more advanced troubleshooting or seek professional help.

5.1 Check the Ignition System

Ignition Coil: Test the ignition coil to ensure it’s producing a strong spark.
Wiring: Inspect the wiring for any signs of damage or corrosion.
Tool List: Multimeter.
Why it Matters: A faulty ignition system can prevent the engine from starting.

5.2 Seek Professional Assistance

Qualified Technician: Take your chainsaw to a qualified technician for diagnosis and repair.
Stihl Dealer: Contact your local Stihl dealer for assistance.
Why it Matters: A professional technician has the tools, knowledge, and experience to diagnose and repair complex chainsaw problems.

Safety First: Important Precautions

Disconnect the Spark Plug: Always disconnect the spark plug before working on the chainsaw to prevent accidental starting.
Wear Safety Glasses: Wear safety glasses to protect your eyes from debris.
Wear Gloves: Wear gloves to protect your hands from sharp objects and chemicals.
Work in a Well-Ventilated Area: Work in a well-ventilated area to avoid breathing harmful fumes.
Follow Instructions: Always follow the instructions in your Stihl MS291 owner’s manual.

Preventative Maintenance: Keeping Your Chainsaw Running Smoothly

Regular Cleaning: Clean your chainsaw regularly to remove dirt, debris, and sawdust.
Proper Lubrication: Lubricate the chain, bar, and starter mechanism regularly.
Sharpen the Chain: Keep the chain sharp to reduce strain on the engine.
Use Fresh Fuel: Use fresh fuel and the correct fuel-to-oil ratio.
Store Properly: Store your chainsaw in a dry place when not in use.

Case Study: The Resilient MS291

I recall a project where we were clearing a heavily wooded area after a storm. One of our MS291s developed a hard-to-pull starter. Initially, we suspected a major engine issue, given the heavy use it had endured. However, after systematically going through the troubleshooting steps outlined in this guide, we discovered the culprit was a combination of a dirty air filter and a slightly worn recoil spring. Replacing the spring and thoroughly cleaning the air filter restored the chainsaw to perfect working order. This experience reinforced the importance of starting with the simple checks and not jumping to conclusions about major repairs.

Actionable Metrics: Measuring Success

Starting Time: Track the time it takes to start your chainsaw. A properly functioning chainsaw should start within a few pulls.
Compression Reading: Monitor the engine’s compression reading. A significant drop in compression indicates a potential problem.
Maintenance Schedule: Adhere to a regular maintenance schedule to prevent problems from developing.

Global Considerations: Adapting to Different Environments

Chainsaw maintenance and troubleshooting can vary depending on the environment. In dusty or humid climates, air filter cleaning and lubrication become even more critical. Fuel quality can also vary significantly, so it’s important to use high-quality fuel and the correct fuel-to-oil ratio.

Common Mistakes to Avoid

Over-Priming: Over-priming the engine can lead to hydro lock.
Using Incorrect Fuel Mix: Using the wrong fuel-to-oil ratio can damage the engine.
Ignoring Warning Signs: Ignoring warning signs, such as a hard-to-pull starter cord, can lead to more serious problems.
Neglecting Maintenance: Neglecting regular maintenance can shorten the lifespan of your chainsaw.

Latest Logging Tools and Technologies

While the Stihl MS291 is a reliable workhorse, advancements in logging tools and technologies are constantly emerging. Battery-powered chainsaws are becoming increasingly popular for their reduced noise and emissions. New chain designs and sharpening techniques can improve cutting efficiency and reduce strain on the engine. Staying informed about these advancements can help you optimize your wood processing operations.

Conclusion: Mastering the Art of Chainsaw Maintenance

Troubleshooting a hard-to-pull starter cord on a Stihl MS291 can seem daunting, but with a systematic approach and a little patience, you can often resolve the issue yourself. Remember to start with the simple checks, move to lubrication, and then delve into the more complex components if needed. Regular maintenance and preventative measures are key to keeping your chainsaw running smoothly for years to come. By following the steps outlined in this guide, you’ll be well-equipped to tackle this common problem and keep your Stihl MS291 in top condition. The next step is to gather your tools, inspect your chainsaw, and start troubleshooting! Good luck, and happy cutting!