Stihl 028 Super Engine & Bar Length (Sizing Guide)
The STIHL 028 Super has a 51.5 cm³ engine. For routine ground-level cutting, a 16–20-inch bar is a practical range, but the correct setup depends on the saw’s exact version and the bar, chain, and sprocket fitted. Check the bar stamp and manual before buying parts; match pitch, gauge, and drive-link count, then choose the shortest suitable bar.
If you are setting up an older 028 Super, the choice is not simply “longer bar equals more reach.” A longer bar can add cutting load and increase exposure to kickback, especially if the chain is dull or the wood is large and hard. Getting the fit right starts with identifying the saw and its current parts, not trusting a seller’s description or a bar length alone.
I use a simple rule when assessing an older saw: verify each part of the cutting system before replacing any one piece. The engine, bar mount, sprocket, and chain must agree. That check helps you avoid buying a chain that almost fits, or a bar that looks right but does not match the saw.
What the 028 Super engine can tell you
The 028 Super is a 51.5 cm³ two-stroke chainsaw. Displacement describes the volume swept by the engine’s piston; it does not, by itself, identify the correct bar or chain. Use the model and serial information, the saw’s manual, and the markings on the fitted parts to guide replacement choices.
The 028 Super is an older model, so parts may have been changed during its working life. A saw may now have a different bar, sprocket, or clutch setup from its original configuration. Treat the parts currently fitted as clues, not proof that they are correct.
Look for the model designation and serial number on the saw, then use them to identify the right operator’s manual or ask a qualified STIHL dealer to confirm the variant. If the model cannot be confirmed, do not guess at specifications such as permitted bar lengths, idle speed, or maximum no-load RPM. Those limits must come from the correct manual.
A healthy engine also matters to bar choice. A longer bar puts more chain in the cut and can make the saw work harder. If the engine is weak, the chain is dull, or the saw does not oil properly, adding bar length will not solve the problem.
Choosing a bar length for the 028 Super
Bar length is the usable cutting length along the guide bar, not the bar’s total length from end to end. For routine ground-level cutting, 16–20 inches is a practical range for a sound 028 Super, provided the exact manual and the saw’s bar mount allow the chosen bar.
A 16-inch bar is often the more manageable choice for routine firewood and smaller cuts. A 18- or 20-inch bar can provide more reach when the job calls for it, but it increases cutting load. For hard, large-diameter wood, a shorter bar may help the saw work more freely. Choose the shortest bar that can safely reach the intended cut.
| Bar length | Practical use | What to consider |
|---|---|---|
| 16 in. | Routine ground-level work and smaller wood | More manageable; still confirm mount and chain fit |
| 18 in. | General cutting where extra reach is useful | Keep the chain sharp and check engine condition |
| 20 in. | Larger cuts when the saw and manual permit it | More load and kickback exposure; avoid forcing cuts |
| Longer than 20 in. | Not a default choice | Confirm the exact manual and full parts compatibility first |
This table is a sizing guide, not a promise that every 028 Super accepts every length shown. The permitted range may depend on the model variant and current parts. If a bar seems to need extra force to cut, stop and check chain sharpness, tension, wood condition, and engine performance rather than leaning harder on the saw.
Match the bar, chain, and sprocket
Pitch is the spacing system that matches the chain to the sprocket and bar tip. Gauge is the thickness of the chain’s drive links, which must fit the bar groove. Drive-link count is the number of links that run around the bar; it varies with bar length and the specific bar.
Common 028 Super setups use a 3/8-inch pitch chain. The bar gauge is specific to the bar, and .063 inch is common, but do not assume either value for the parts on your saw. Read the bar stamp and inspect the sprocket marking, then confirm that all three components match.
Before ordering, record:
- The pitch marked on the bar or sprocket.
- The bar’s gauge, often stamped on the bar.
- The required drive-link count for that exact bar.
- The bar mount and any model-specific fit details.
- The chain type and specifications given by its maker.
Do not select a chain from bar length alone. Two bars of the same length may need different drive-link counts, and a chain with the wrong pitch or gauge will not fit correctly. If the markings are worn away, compare the parts with the manual or have a dealer identify them before purchase.
Real-world setup checks: three common situations
These examples show how I would work through common setup decisions. They are practical scenarios, not claims that one bar length is right for every saw. In each case, the bar stamp and sprocket must agree, and the manual for the saw’s variant remains the final check.
Scenario 1: A saw used for routine firewood. The owner wants a replacement for a worn bar. I would first verify the existing bar mount, pitch, gauge, and chain length. If the saw is healthy and the manual permits it, a 16- or 18-inch bar may suit routine ground-level work. I would not order a chain until I had its required drive-link count.
Scenario 2: A 20-inch bar is already fitted. The owner reports slow cutting in dense wood. I would check chain sharpness and tension, oil delivery, and engine condition before blaming the bar. If the chain binds or the engine labors, a shorter bar may be a better match for that work, but only after the cutting system is checked and the manual confirms fit.
Scenario 3: The bar has no readable stamp. A seller says the chain is “standard 028.” That is not enough to confirm compatibility. I would identify the sprocket pitch and bar groove gauge, then ask a dealer or parts supplier to confirm the mount and chain length for the exact bar. Guessing can lead to a mismatched chain or unsafe operation.
These checks are especially useful when buying a used saw or replacement parts online. Ask for clear photos of the model and serial area, bar stamp, and sprocket. If those details cannot be verified, pause the purchase rather than relying on a broad claim that a part “fits an 028.”
Fuel, lubrication, and safe operation
Fuel mix is the ratio of gasoline to two-stroke oil. Use the ratio stated in the correct operator’s manual. A 50:1 mix applies when using STIHL HP Ultra or another oil explicitly rated for 50:1 use; do not infer the ratio from the saw’s age. Read both the manual and the oil label, and keep fuel separate from chain oil.
Use proper chain-and-bar oil and confirm that oil reaches the chain. Bar-oil flow can vary with the saw’s adjustment and operating conditions, so do not rely on an assumed flow rate. Check the manual for the procedure and stop if lubrication is not working.
Before cutting, check the chain brake, throttle lockout, chain catcher, controls, fasteners, bar, chain tension, and oiling system. Wear a helmet with face and eye protection, hearing protection, chainsaw-rated leg protection, gloves, and protective boots. Clear your footing, escape route, bystanders, and overhead hazards. Assess lean, wind, defects, and wood under tension or compression.
Keep both hands on the saw and the bar nose clear of wood and other objects. Upper-quadrant kickback happens when the upper part of the bar nose contacts something and drives the bar rapidly upward and toward the operator. A chain brake is not a substitute for sound technique. Avoid cutting above shoulder height, and do not use the saw for aerial tree work unless qualified and properly equipped.
Use a sharp, correctly matched chain. If the kerf closes, the saw binds, or the stem shifts, stop and reassess rather than forcing the cut. Felling requires a competent assessment and a planned notch, hinge, and escape route. Follow the manual and applicable work rules, including ANSI Z133 practices where relevant and OSHA 29 CFR 1910.266 when the work falls under its logging rules.
Maintenance, sharpening, and storage
Chain depth gauges, often called rakers, control how deeply each cutter bites. There is no single setting that suits every chain. Follow the chain maker’s specification and use its depth-gauge tool; do not file by guesswork. File the cutters to the maker’s angles, and replace damaged or worn parts.
For carburetor tuning, use the exact manual’s idle and maximum no-load RPM limits and a tachometer. Do not tune by ear or raise the maximum speed beyond the stated limit. If the right specification is unavailable, have a qualified technician check the saw.
After cutting, engage the brake, shut off the engine, and let the saw cool before maintenance or refueling. Clean the air filter, sprocket cover, bar groove, and oil holes. Inspect the bar and chain for damage and check chain tension. For extended storage, follow the manual’s fuel procedure, clean the saw, protect the bar and chain, and keep fuel and chain oil in labeled, approved containers.
Quick answers about 028 Super bar sizing
How big is the 028 Super engine?
Its displacement is 51.5 cm³.
What bar length should I use?
For routine ground-level cutting, 16–20 inches is a practical range if the exact manual and saw parts permit it. Choose the shortest bar that safely reaches the cut.
Can an 028 Super use a 20-inch bar?
Some setups may use one, but confirm the saw’s variant, bar mount, sprocket, and manual first. A longer bar adds cutting load and kickback exposure.
What chain pitch is common on an 028 Super?
Common setups use 3/8-inch pitch. Verify the pitch on the fitted bar and sprocket rather than assuming it applies to your saw.
Is the chain gauge always .063 inch?
No. That gauge is common, but the correct gauge is the one stamped on the bar and matched to its groove.
How do I find the right drive-link count?
Read the bar information or check the bar maker’s specifications. Count depends on the exact bar and length, so do not order by length alone.
What fuel ratio should I use?
Follow the correct manual and oil label. A 50:1 mix applies with STIHL HP Ultra or another oil explicitly rated for that ratio.
Can I fit a longer bar if the saw cuts slowly?
A longer bar is unlikely to fix slow cutting. Check chain sharpness, tension, oil delivery, and engine condition; consider a shorter bar if the work demands it.
How can I confirm a used bar will fit?
Check the mount, bar stamp, pitch, gauge, and drive-link count, and confirm sprocket compatibility. If the markings are unclear, have a qualified dealer identify the parts.
Should I use the chain brake as my main kickback protection?
No. Keep the bar nose clear, use a firm two-handed grip, and follow safe cutting practice. The brake does not replace control or training.
The practical choice
A 16–20-inch bar is a useful starting range for a healthy 028 Super doing routine ground-level work, not a universal fit guarantee. Confirm the manual and saw variant, then match the bar, chain, and sprocket by mount, pitch, gauge, and drive-link count. When in doubt, verify the parts before buying or cutting.
(This article was written by one of our staff writers, Elliott Fowler. Visit our Meet the Team page.)
