Stihl 36 Inch Bar: Best Upgrade Tips For MS 500i (Pro Guide)

The hidden benefit of upgrading to a 36-inch bar on your Stihl MS 500i isn’t just about cutting bigger trees faster. It’s about unlocking the full potential of a beast of a chainsaw, improving your efficiency, and ultimately, making your wood processing endeavors more enjoyable and less strenuous. I’ve seen too many folks limit their MS 500i with a shorter bar, unknowingly leaving significant power untapped. This guide isn’t just about slapping on a longer bar; it’s about doing it right, understanding the nuances, and maximizing the benefits. I’ll walk you through the process, sharing lessons learned from years of felling, bucking, and processing timber.

Stihl 36 Inch Bar: Best Upgrade Tips for MS 500i (Pro Guide)

The Stihl MS 500i is a groundbreaking chainsaw, known for its exceptional power-to-weight ratio, fuel injection system, and overall performance. However, the bar length that comes standard might not always be optimal for every application. This guide explores the advantages of upgrading to a 36-inch bar, providing detailed steps, safety considerations, and expert tips to ensure a successful upgrade and enhanced cutting experience.

Why Upgrade to a 36-Inch Bar on Your MS 500i?

Before diving into the how-to, let’s address the “why.” The MS 500i is a powerhouse, and a longer bar allows you to leverage that power more effectively, especially when dealing with larger diameter trees.

Increased Reach: A 36-inch bar provides the reach needed to fell larger trees in a single pass, reducing the need for multiple cuts and repositioning. This is crucial for efficiency and safety, especially in challenging terrain.
Enhanced Leverage: The added length provides better leverage, making it easier to control the saw and maintain a straight cut. This is particularly beneficial when bucking large logs.
Improved Efficiency: For larger timber, a longer bar simply gets the job done faster. Less time spent cutting means more time processing and stacking firewood or milling lumber.
Reduced Strain: While it might seem counterintuitive, using a longer bar on a powerful saw like the MS 500i can actually reduce strain. By making fewer cuts and leveraging the saw’s power, you exert less physical effort.

I remember one specific job where I was felling some massive oaks for a client. With my standard 28-inch bar, each tree required multiple cuts, which was exhausting and time-consuming. After switching to a 36-inch bar, the difference was night and day. I was able to drop the trees with fewer cuts, saving me significant time and energy.

Understanding Key Concepts

Before we proceed, let’s define some key terms:

Green Wood vs. Seasoned Wood: Green wood is freshly cut wood with high moisture content. Seasoned wood has been dried, reducing its moisture content. Green wood is easier to split, while seasoned wood burns more efficiently.
Bar Oil: A specialized oil designed to lubricate the chainsaw bar and chain, reducing friction and wear.
Chain Pitch: The distance between three consecutive rivets on the chain, divided by two. This must match the sprocket and bar.
Chain Gauge: The thickness of the drive links on the chain that fit into the bar groove. This also must match the bar and sprocket.
Kerf: The width of the cut made by the chainsaw chain.
Felling: The process of cutting down a tree.
Bucking: The process of cutting a felled tree into shorter lengths.
Limbing: The process of removing branches from a felled tree.

Step-by-Step Guide to Upgrading to a 36-Inch Bar

Here’s a detailed guide to upgrading your MS 500i to a 36-inch bar:

Step 1: Gather Your Tools and Materials

36-Inch Chainsaw Bar: Ensure it’s compatible with the Stihl MS 500i. I recommend a Stihl Rollomatic E or ES Light bar for its durability and performance. Check the bar mount pattern to ensure compatibility.
Chainsaw Chain: Choose a chain with the correct pitch, gauge, and number of drive links for your new bar. Typically, a .404″ pitch chain is recommended for larger bars on the MS 500i.
Chainsaw Wrench (Scrench): For removing and tightening the bar nuts and adjusting chain tension.
File and Filing Guide: For sharpening the chain.
Chain Breaker/Joiner (Optional): For adjusting chain length if needed.
Bar Oil: High-quality bar oil to lubricate the chain and bar.
Work Gloves: To protect your hands.
Safety Glasses: To protect your eyes from flying debris.
Hearing Protection: Chainsaws are loud; protect your hearing.
Chainsaw Chaps: Essential for leg protection.
First Aid Kit: In case of an accident.

Step 2: Preparing Your Chainsaw

Safety First: Engage the chain brake and remove the spark plug wire to prevent accidental starting.
Clean the Saw: Use a brush and compressed air to remove any sawdust or debris from the saw body, especially around the bar mounting area.
Inspect the Sprocket: Check the sprocket for wear. A worn sprocket can damage the chain and reduce cutting efficiency. Replace it if necessary. The MS 500i typically uses a spur sprocket, but a rim sprocket can be installed for easier replacement.
Remove the Existing Bar and Chain: Use the scrench to loosen the bar nuts and remove the side cover. Carefully remove the old bar and chain.

Step 3: Installing the New Bar and Chain

Mount the New Bar: Align the bar mounting studs with the holes in the new bar and slide the bar into place. Ensure the tensioning pin on the saw engages with the tensioning hole on the bar.
Install the New Chain: Drape the chain around the bar, ensuring the cutting teeth are facing the correct direction (they should point forward on the top of the bar). Engage the drive links of the chain with the sprocket.
Reinstall the Side Cover: Place the side cover back on the saw, aligning the bar nuts with the studs.
Adjust Chain Tension: Tighten the bar nuts finger-tight. Use the chain tensioning screw to adjust the chain tension. The chain should be snug against the bar but still able to be pulled around by hand. A good rule of thumb is to be able to pull the chain about 1/8 inch away from the bar in the middle.
Tighten the Bar Nuts: Once the chain tension is properly adjusted, fully tighten the bar nuts with the scrench.

Step 4: Checking and Adjusting Chain Tension

Initial Tension Check: After tightening the bar nuts, recheck the chain tension. It may have changed slightly.
Running Test: Start the chainsaw (reconnect the spark plug wire). With the chain brake engaged, run the saw at idle for a few seconds. This helps seat the chain on the bar.
Re-Tension: Stop the saw and recheck the chain tension. Adjust as needed. The chain will stretch slightly during initial use, so it’s important to monitor the tension closely.

Step 5: Lubrication and Break-In

Fill the Bar Oil Reservoir: Ensure the bar oil reservoir is full.
Initial Lubrication: Start the saw and engage the chain brake. Run the saw at a slightly higher RPM for a few seconds to ensure the chain is properly lubricated. You should see a fine mist of oil being thrown off the chain.
Break-In Period: For the first few cuts, take it easy on the saw. Avoid forcing it through the wood. This allows the chain and bar to properly break in.

Step 6: Sharpening the Chain

A sharp chain is essential for efficient and safe cutting.

Inspect the Chain: Regularly inspect the chain for damage or dullness.
Sharpening: Use a file and filing guide to sharpen the chain. Maintain the correct filing angle and depth. I prefer a 7/32″ round file for most .404″ pitch chains.
Depth Gauges: Check and adjust the depth gauges (rakers) as needed. Lower depth gauges allow the chain to take a deeper bite, but too low can cause excessive vibration and kickback.

I’ve found that a well-sharpened chain can make even the toughest wood feel like butter. It’s worth taking the time to learn how to sharpen your chain properly.

Safety Considerations

Upgrading to a longer bar increases the potential for kickback and other hazards. Always prioritize safety:

Wear Appropriate PPE: Always wear safety glasses, hearing protection, chainsaw chaps, and work gloves.
Maintain a Firm Grip: Keep a firm grip on the chainsaw with both hands.
Proper Stance: Maintain a stable stance with your feet shoulder-width apart.
Be Aware of Kickback: Understand the dangers of kickback and how to avoid it. Kickback occurs when the tip of the bar contacts an object, causing the saw to suddenly thrust back towards the operator.
Avoid Cutting Above Shoulder Height: This increases the risk of losing control of the saw.
Never Cut with the Tip of the Bar: This is a common cause of kickback.
Clear the Work Area: Remove any obstacles from the work area.
Work in a Well-Ventilated Area: Chainsaw exhaust contains harmful fumes.
Inspect the Saw Regularly: Check for loose parts, damaged components, and proper lubrication.
Take Breaks: Fatigue can lead to accidents. Take frequent breaks to rest and rehydrate.

Choosing the Right Chain

Selecting the correct chain is crucial for optimal performance and safety.

Pitch: As mentioned earlier, the pitch must match the sprocket and bar. A .404″ pitch chain is generally recommended for larger bars on the MS 500i.
Gauge: The gauge must also match the bar. Common gauges for the MS 500i are .063″ and .058″.
Drive Links: The number of drive links must match the bar length. A 36-inch bar typically requires around 114 drive links.
Chain Type: There are different types of chains available, each designed for specific applications.
- Full Chisel: Aggressive cutting, best for clean wood.
- Semi-Chisel: More durable, better for dirty or frozen wood.
- Low-Kickback: Designed to reduce the risk of kickback, suitable for inexperienced users.
Chain Brands: Stihl, Oregon, and Husqvarna are reputable chain brands. I’ve had good experiences with Stihl chains, but Oregon chains are also a solid choice.

Maintenance and Care

Proper maintenance is essential for prolonging the life of your bar and chain.

Regular Cleaning: Clean the bar groove regularly to remove sawdust and debris. Use a bar groove cleaner or a flat screwdriver.
Bar Oil: Use high-quality bar oil to lubricate the chain and bar. Avoid using motor oil or other substitutes.
Chain Sharpening: Keep the chain sharp. A dull chain puts unnecessary strain on the saw and increases the risk of kickback.
Bar Dressing: Use a bar dressing tool to remove burrs and even out the bar rails.
Chain Rotation: Rotate the chain regularly to ensure even wear.
Storage: Store the chainsaw in a dry place, away from direct sunlight and extreme temperatures. Drain the fuel tank before storing the saw for extended periods.

Troubleshooting

Here are some common issues you might encounter and how to resolve them:

Chain Won’t Cut:
- Dull Chain: Sharpen the chain.
- Incorrect Depth Gauge Setting: Adjust the depth gauges.
- Insufficient Bar Oil: Check the bar oil reservoir and oiler function.
- Incorrect Chain Tension: Adjust the chain tension.
Chain Keeps Coming Off the Bar:
- Worn Sprocket: Replace the sprocket.
- Incorrect Chain Tension: Adjust the chain tension.
- Damaged Bar: Inspect the bar for damage and replace if necessary.
Saw Vibrates Excessively:
- Dull Chain: Sharpen the chain.
- Loose Bar Nuts: Tighten the bar nuts.
- Worn Anti-Vibration Mounts: Replace the anti-vibration mounts.
Saw Smokes Excessively:
- Insufficient Bar Oil: Check the bar oil reservoir and oiler function.
- Dull Chain: Sharpen the chain.
- Overheating Engine: Allow the engine to cool down.

Strategic Advantages and Benefits

Upgrading to a 36-inch bar on your MS 500i offers several strategic advantages:

Increased Productivity: The longer bar allows you to fell and buck larger trees more efficiently, increasing your overall productivity.
Reduced Labor Costs: By completing jobs faster, you can reduce labor costs.
Improved Safety: With proper technique and safety precautions, a longer bar can actually improve safety by reducing the need for multiple cuts and repositioning.
Enhanced Versatility: The MS 500i with a 36-inch bar can handle a wider range of tasks, from felling large trees to milling lumber.
Higher Quality Results: The increased leverage and control provided by a longer bar can result in cleaner, straighter cuts.

Case Study: Felling Large Diameter Oak Trees

I recently worked on a project where I had to fell several large diameter oak trees. These trees were over 40 inches in diameter, and my standard 28-inch bar wasn’t cutting it (pun intended!).

Challenge: Felling large diameter oak trees with a standard bar was time-consuming and physically demanding. It required multiple cuts and repositioning, which increased the risk of accidents.

Solution: I upgraded to a 36-inch bar on my MS 500i and used a full chisel chain.

Results: The upgrade significantly improved my efficiency. I was able to fell the trees with fewer cuts, saving me time and energy. The longer bar also provided better leverage, making it easier to control the saw and maintain a straight cut.

Data:

Time Savings: The upgrade reduced the felling time by approximately 30%.
Energy Savings: I experienced significantly less fatigue after switching to the longer bar.
Improved Cut Quality: The cuts were cleaner and straighter, resulting in less waste.

Lessons Learned: Upgrading to a longer bar can be a game-changer when dealing with large diameter trees. However, it’s important to use proper technique and safety precautions.

Cost Analysis

The cost of upgrading to a 36-inch bar on your MS 500i will vary depending on the brand and type of bar and chain you choose. Here’s a rough estimate:

36-Inch Chainsaw Bar: \$150 – \$300
Chainsaw Chain: \$50 – \$100
Total Cost: \$200 – \$400

While the initial cost may seem significant, the increased productivity and efficiency can quickly offset the investment.

Drying Methods and Moisture Content Targets

Understanding wood drying is crucial for firewood preparation and woodworking.

Air Drying: The most common and cost-effective method. Stack the firewood in a well-ventilated area, off the ground, and covered to protect it from rain and snow. Air drying typically takes 6-12 months, depending on the wood species and climate.
Kiln Drying: A faster method that uses controlled heat and humidity to dry the wood. Kiln drying can reduce the drying time to a few weeks.
Moisture Content Targets:
- Firewood: 15-20% moisture content for optimal burning.
- Woodworking: 6-8% moisture content for stability and prevent warping.

I’ve found that air drying is the most practical method for firewood preparation. I typically stack my firewood in the spring and let it dry over the summer and fall. By winter, it’s ready to burn.

Firewood Stacking Techniques

Proper firewood stacking is essential for efficient drying and storage.

Off the Ground: Stack the firewood on pallets or timbers to keep it off the ground and prevent moisture absorption.
Well-Ventilated: Leave space between the rows of firewood to allow for air circulation.
Covered: Cover the top of the firewood stack to protect it from rain and snow.
Neat and Organized: Stack the firewood neatly and securely to prevent it from collapsing.

I prefer to use the “Holz Hausen” method for stacking firewood. This is a circular stack that provides excellent ventilation and stability.

Next Steps and Implementation Guidance

Now that you’ve learned about upgrading to a 36-inch bar on your MS 500i, it’s time to put this knowledge into practice.

Assess Your Needs: Determine if a 36-inch bar is right for your specific applications.
Gather Your Tools and Materials: Purchase the necessary tools and materials, including the bar, chain, scrench, file, and bar oil.
Follow the Step-by-Step Guide: Carefully follow the instructions outlined in this guide to install the new bar and chain.
Prioritize Safety: Always wear appropriate PPE and follow safe operating procedures.
Practice and Experiment: Take the time to practice and experiment with the new bar and chain.
Maintain Your Equipment: Regularly maintain your chainsaw to ensure optimal performance and longevity.

Conclusion

Upgrading to a 36-inch bar on your Stihl MS 500i can significantly enhance your wood processing capabilities. By following the steps outlined in this guide and prioritizing safety, you can unlock the full potential of your chainsaw and make your work more efficient and enjoyable. Remember, the key is to understand the nuances of the equipment, respect its power, and always prioritize safety. Happy cutting!

Stihl 36 Inch Bar: Best Upgrade Tips for MS 500i (Pro Guide)

Stihl 36 Inch Bar: Best Upgrade Tips for MS 500i (Pro Guide)