Stihl Chainsaw Starts Then Dies (5 Electronic Ignition Fixes)

The sharp, sweet scent of freshly cut pine hangs heavy in the air, mixing with the metallic tang of bar oil and hot engine. That familiar symphony of a Stihl chainsaw roaring to life, then sputtering and dying, is enough to make any woodcutter’s blood run cold. It’s a frustrating scenario, especially when you’re staring down a mountain of logs and daylight is burning. But before you resign yourself to a day of head-scratching and muttered curses, let’s troubleshoot. This article dives deep into the potential electronic ignition issues causing your Stihl chainsaw to start then die, offering practical fixes and, importantly, a realistic look at the costs involved in getting your saw back in action. I’ll share some personal experiences and insights that will help you navigate the repair process, keeping your budget in check.

Stihl Chainsaw Starts Then Dies: 5 Electronic Ignition Fixes

A chainsaw that starts and immediately dies often points to an issue within the ignition system, impacting the spark needed for continuous combustion. While fuel delivery and air intake are vital, let’s focus on the electronic ignition components, their potential faults, and how to address them.

1. Faulty Spark Plug: The Foundation of Ignition

The spark plug is the heart of the ignition system. It provides the spark that ignites the fuel-air mixture. When it fails, the engine might start briefly but will quickly die due to inconsistent or non-existent spark.

Diagnosis: Remove the spark plug and inspect it. Look for cracks in the ceramic insulator, excessive carbon buildup, or a worn electrode. A healthy spark plug should have a clean, dry appearance. Use a spark plug tester to verify the spark. A weak or absent spark indicates a problem.
Fix: Replace the spark plug with the correct type specified for your Stihl chainsaw model. This is typically a low-cost fix.
Cost: A new spark plug typically costs between $5 and $15, depending on the brand and type. I always keep a few spares on hand; they’re cheap insurance against downtime.
- Personal Experience: I once spent a whole morning wrestling with a chainsaw that wouldn’t stay running. After checking everything else, I finally pulled the spark plug. It looked okay at first glance, but a closer inspection revealed a hairline crack in the ceramic. A $7 spark plug and 5 minutes later, the saw was roaring again.

2. Defective Ignition Coil: The Spark Amplifier

The ignition coil amplifies the low voltage from the magneto (or other power source) to the high voltage needed to create a spark at the spark plug. A failing ignition coil can produce a weak or intermittent spark, leading to the starting-then-dying symptom.

Diagnosis: Use a multimeter to test the primary and secondary resistance of the ignition coil. Compare your readings to the specifications in your chainsaw’s service manual. A reading outside the specified range indicates a faulty coil.
Fix: Replace the ignition coil. This is a more involved repair than replacing a spark plug, but it’s usually manageable with basic mechanical skills.
Cost: Ignition coils for Stihl chainsaws typically range from $30 to $80, depending on the model and brand.
- Cost Considerations: When replacing the ignition coil, consider the source of the replacement part. OEM (Original Equipment Manufacturer) parts are generally more reliable but also more expensive. Aftermarket parts can be a cost-effective alternative, but research the brand and read reviews to ensure quality.
- Example: I had a Stihl MS 290 Farm Boss that was giving me fits. After replacing the spark plug, fuel filter, and cleaning the carburetor, I finally tested the ignition coil. The secondary resistance was way out of spec. I opted for an aftermarket coil from a reputable brand for around $45, and it solved the problem. It’s been running strong for two years since.

3. Failing Flywheel: The Ignition System’s Timing Master

The flywheel contains magnets that induce a voltage in the ignition coil as it rotates. If the magnets are weak or the flywheel is damaged, the ignition system won’t generate enough voltage to create a consistent spark.

Diagnosis: Visually inspect the flywheel for damage, such as cracks or broken magnets. You can also use a multimeter to check the continuity of the magnets.
Fix: If the flywheel is damaged, it needs to be replaced. This can be a more complex repair, as it often involves removing the starter assembly and other components.
Cost: Flywheels for Stihl chainsaws can range from $50 to $150, depending on the model.
- Cost-Saving Tip: Before replacing the flywheel, make sure the air gap between the flywheel and the ignition coil is correct. An incorrect air gap can also cause ignition problems. The correct air gap is usually specified in your chainsaw’s service manual.

4. Shorted Kill Switch: The Unexpected Interrupter

The kill switch is designed to ground the ignition system, stopping the engine. If the kill switch is faulty or the wiring is damaged, it can inadvertently ground the ignition system, causing the engine to die shortly after starting.

Diagnosis: Disconnect the kill switch wire from the ignition coil. If the chainsaw runs normally with the kill switch disconnected, the switch or its wiring is the problem.
Fix: Replace the kill switch or repair the wiring. This is usually a relatively simple and inexpensive repair.
Cost: A new kill switch typically costs between $10 and $20.
- Troubleshooting Tip: Sometimes, the kill switch wiring can become frayed or damaged, causing it to short against the engine housing. Carefully inspect the wiring for any signs of damage.

5. Defective Module/Igniter: The Electronic Brain

Some Stihl chainsaw models use an electronic ignition module (also called an igniter) to control the timing and intensity of the spark. If this module fails, it can cause the engine to start briefly and then die.

Diagnosis: Testing an ignition module typically requires specialized equipment, such as an oscilloscope. However, you can try replacing the module with a known good one to see if that solves the problem.
Fix: Replace the ignition module. This is usually a more expensive repair than replacing other ignition components.
Cost: Ignition modules for Stihl chainsaws can range from $80 to $200, depending on the model.
- Cost Justification: Replacing the ignition module can be a significant expense. Before replacing it, make sure you’ve ruled out all other possible causes, such as a faulty spark plug, ignition coil, or kill switch.

The True Cost of Firewood: A Deep Dive into Budgeting

Now that we’ve addressed the potential ignition problems, let’s shift gears and talk about the bigger picture: the true cost of firewood. Many people underestimate the expenses involved in sourcing, processing, and storing firewood. I’ve learned this the hard way over the years, and I’m here to share my insights to help you avoid costly mistakes.

Variable Factors Affecting Firewood Costs

The cost of firewood varies significantly depending on several factors:

Wood Type: Hardwoods like oak, maple, and hickory generally cost more than softwoods like pine and fir. Hardwoods burn hotter and longer, providing more heat per cord.
Location Accessibility: If you have easy access to a woodlot or forest, you can potentially save money by harvesting your own firewood. However, if you need to purchase firewood from a dealer, the cost will be higher due to transportation and handling expenses.
Seasonality: Firewood prices typically increase during the fall and winter, when demand is highest. Buying firewood in the spring or summer can save you money.
Moisture Content: Green (unseasoned) firewood is cheaper than seasoned firewood, but it’s much harder to burn and produces less heat. You’ll need to factor in the cost of storing and drying green firewood.
Labor Costs: If you’re hiring someone to cut, split, and stack your firewood, labor costs will be a significant expense.

Breaking Down Firewood Cost Components

To accurately budget for firewood, it’s essential to break down all the cost components:

Timber Purchase or Harvesting Costs:
- Purchasing Timber: If you’re buying timber from a landowner or logging company, the cost will depend on the species, volume, and quality of the wood. Timber prices vary widely depending on location and market conditions.
  - Data Point: According to the USDA Forest Service, the average stumpage price (the price paid to the landowner for standing timber) for hardwood sawtimber in the Eastern United States in 2023 was around $300 per thousand board feet (MBF). However, prices can range from $100 to $500+ per MBF depending on the species and quality.
- Harvesting Your Own Timber: If you’re harvesting your own timber, you’ll need to factor in the cost of permits (if required), equipment rental, and labor.
  - Permitting Costs: Firewood permits can vary widely depending on your location. In some areas, they may be free or very inexpensive, while in others, they can cost several hundred dollars. Always check with your local forestry agency to determine the permit requirements in your area.
  - Equipment Rental: If you don’t own a chainsaw, log splitter, or other necessary equipment, you’ll need to rent it. Rental costs can add up quickly.
    - Cost Example: Renting a chainsaw for a day typically costs between $30 and $50. Renting a log splitter for a day can cost between $75 and $150.
    - Tool Maintenance and Repair Costs:
- Chainsaw Maintenance: Regular chainsaw maintenance is essential to keep your saw running smoothly and safely. This includes sharpening the chain, cleaning the air filter, replacing the spark plug, and lubricating the bar and chain.
  - Cost Example: A chainsaw chain sharpening service typically costs between $10 and $20. A new chainsaw chain can cost between $20 and $50.
- Log Splitter Maintenance: Log splitters also require regular maintenance, such as changing the hydraulic fluid, lubricating the moving parts, and inspecting the hoses for leaks.
  - Cost Example: A hydraulic fluid change for a log splitter typically costs between $20 and $40.
  - Labor Wages:
- Hiring Labor: If you’re hiring someone to help you cut, split, and stack your firewood, you’ll need to pay them a fair wage. Labor rates vary depending on experience and location.
  - Data Point: According to the Bureau of Labor Statistics, the median hourly wage for logging workers in the United States in May 2022 was $20.95. However, wages can range from $15 to $30+ per hour depending on experience and location.
- Opportunity Cost: Even if you’re doing the work yourself, it’s important to consider the opportunity cost of your time. How much is your time worth? What else could you be doing with that time?
- Fuel Costs:
- Chainsaw Fuel: Chainsaws require a mixture of gasoline and oil. The cost of fuel can add up quickly, especially if you’re cutting a lot of firewood.
  - Cost Example: A gallon of chainsaw fuel (gasoline and oil mix) typically costs between $5 and $8.
- Transportation Fuel: You’ll also need to factor in the cost of fuel for transporting the firewood from the woodlot to your home.
  - Cost Example: If you’re hauling firewood in a pickup truck, you can expect to get around 15-20 miles per gallon. The cost of fuel will depend on the distance you’re traveling and the current price of gasoline.
  - Storage Costs:
- Covering Firewood: Firewood needs to be stored in a dry, well-ventilated area to prevent rot and mold. You may need to purchase a tarp or build a woodshed to protect your firewood from the elements.
  - Cost Example: A heavy-duty tarp can cost between $20 and $50. Building a simple woodshed can cost between $100 and $500, depending on the size and materials.
  - Equipment Depreciation:
- Chainsaw Depreciation: Chainsaws depreciate over time due to wear and tear. You should factor in the cost of replacing your chainsaw every few years.
  - Cost Example: A good quality chainsaw can cost between $300 and $800. If you expect to use your chainsaw for 5 years, you should budget $60 to $160 per year for depreciation.
- Log Splitter Depreciation: Log splitters also depreciate over time. You should factor in the cost of replacing your log splitter every 10-15 years.
  - Cost Example: A good quality log splitter can cost between $1,000 and $3,000. If you expect to use your log splitter for 10 years, you should budget $100 to $300 per year for depreciation.

Industry Benchmarks and Statistical Data

To get a better understanding of firewood prices, it’s helpful to look at industry benchmarks and statistical data.

Average Price per Cord of Firewood: The average price per cord of seasoned firewood in the United States in 2023 was around $250 to $450, depending on the region and wood type. However, prices can range from $150 to $600+ per cord.
- Regional Variations: Firewood prices tend to be higher in urban areas and areas with limited access to woodlots. They tend to be lower in rural areas with abundant timber resources.
- Wood Type Impact: Hardwoods like oak and maple typically cost more than softwoods like pine and fir.
Fuelwood Market Rates: Fuelwood market rates vary depending on location and demand. You can find information on fuelwood market rates from local forestry agencies, firewood dealers, and online sources.

Practical Tips for Cost Optimization and Budget Management

Here are some practical tips for optimizing your firewood costs and managing your budget:

Harvest Your Own Firewood: If you have access to a woodlot or forest, consider harvesting your own firewood. This can save you a significant amount of money, but it requires time, effort, and the right equipment.
- Safety First: Always prioritize safety when harvesting your own firewood. Wear appropriate safety gear, such as a helmet, eye protection, hearing protection, and gloves. Use caution when operating a chainsaw and log splitter.
- Buy Firewood in the Off-Season: Firewood prices are typically lower in the spring and summer. Buying firewood in the off-season can save you money.
- Season Your Own Firewood: Green (unseasoned) firewood is cheaper than seasoned firewood. If you have the space and time, consider buying green firewood and seasoning it yourself.
- Drying Time: Firewood typically takes 6-12 months to season properly. The drying time depends on the wood species, size of the pieces, and climate.
- Consider Alternative Fuel Sources: If firewood prices are too high, consider alternative fuel sources, such as wood pellets, propane, or natural gas.
- Cost Comparison: Compare the cost per BTU (British Thermal Unit) of different fuel sources to determine the most cost-effective option for your needs.
- Maintain Your Equipment: Regular maintenance can extend the life of your chainsaw and log splitter, saving you money on repairs and replacements.
- Shop Around for the Best Prices: Don’t settle for the first firewood dealer you find. Shop around and compare prices from different dealers.
- Negotiate with Firewood Dealers: Don’t be afraid to negotiate with firewood dealers. You may be able to get a better price if you buy in bulk or pay in cash.
- Use Firewood Efficiently: Burn firewood efficiently to maximize heat output and minimize waste.
- Proper Firewood Storage: Store firewood in a dry, well-ventilated area to prevent rot and mold.
- Efficient Firewood Burning Techniques: Use proper firewood burning techniques, such as building a small, hot fire and adding wood gradually.

Calculations and Formulas for Firewood

Here are some relevant calculations and formulas for estimating firewood volume and drying time:

Estimating Volume of Logs in Board Feet:
- Doyle Log Rule: Board Feet = ((Diameter – 4)/4)^2 * Length (in feet)
- Scribner Log Rule: This rule uses log diagrams to estimate board feet based on diameter and length.
- International 1/4-inch Log Rule: This rule provides a more accurate estimate of board feet, especially for smaller logs.
Estimating Volume of Firewood in Cords:
- A cord is a stacked pile of wood measuring 4 feet high, 4 feet wide, and 8 feet long, totaling 128 cubic feet.
- To estimate the number of cords in a pile of firewood, measure the height, width, and length of the pile in feet. Multiply these dimensions together and divide by 128.
Estimating Drying Time Based on Moisture Content:
- The drying time of firewood depends on several factors, including the wood species, size of the pieces, climate, and storage conditions.
- As a general rule, firewood needs to dry to a moisture content of 20% or less to burn efficiently.
- You can use a moisture meter to measure the moisture content of firewood.

Challenges Faced by Small-Scale Loggers and Firewood Suppliers

Small-scale loggers and firewood suppliers face numerous challenges, including:

Fluctuating Timber Prices: Timber prices can fluctuate significantly depending on market conditions, making it difficult for small-scale loggers to plan their operations.
Increasing Equipment Costs: The cost of chainsaws, log splitters, and other logging equipment has been increasing in recent years, making it more difficult for small-scale loggers to compete.
Stringent Regulations: Logging operations are subject to numerous regulations, which can be costly and time-consuming to comply with.
Competition from Large-Scale Operations: Small-scale loggers face stiff competition from large-scale logging operations, which have the resources to operate more efficiently and undercut prices.
Labor Shortages: It can be difficult to find and retain qualified logging workers, especially in rural areas.
Insurance Costs: Logging operations require expensive insurance coverage, which can be a significant burden for small-scale loggers.

Case Studies on Budgeting and Cost Management

Let’s look at a few case studies to illustrate how budgeting and cost management can impact the profitability of firewood operations:

Case Study 1: Sustainable Firewood Operation
- A small-scale logger in Vermont implemented sustainable forestry practices, such as selective harvesting and replanting trees. This allowed them to maintain a consistent supply of high-quality firewood while minimizing environmental impact. They also invested in energy-efficient equipment and implemented waste reduction strategies to lower their operating costs.
- Case Study 2: Urban Firewood Supplier
- A firewood supplier in a large city purchased green firewood in bulk from a rural area and seasoned it themselves. This allowed them to offer seasoned firewood at a lower price than their competitors. They also implemented a delivery service to make it more convenient for customers to purchase firewood.
- Case Study 3: Firewood Cooperative
- A group of small-scale loggers formed a cooperative to share equipment, labor, and marketing resources. This allowed them to reduce their individual costs and compete more effectively with larger operations.

Actionable Takeaways and Next Steps

Planning a wood processing or firewood project? Here’s how to start:

Assess Your Needs: Determine how much firewood you’ll need for the winter and what type of wood you prefer.
Evaluate Your Resources: Do you have access to a woodlot or forest? Do you own the necessary equipment, or will you need to rent it?
Develop a Budget: Estimate the costs of all the components involved in sourcing, processing, and storing firewood.
Explore Cost-Saving Strategies: Look for ways to reduce your costs, such as harvesting your own firewood, buying in the off-season, or seasoning your own firewood.
Implement Your Plan: Put your plan into action and start sourcing, processing, and storing your firewood.
Monitor Your Progress: Track your expenses and adjust your budget as needed.

Conclusion

Budgeting for firewood and wood processing can seem daunting, but with careful planning and cost management, you can save money and ensure a steady supply of fuel for the winter. Remember to factor in all the cost components, shop around for the best prices, and explore cost-saving strategies. Whether you’re a seasoned logger or a weekend woodcutter, these tips will help you make informed decisions and manage your resources effectively. And if your Stihl chainsaw starts then dies, don’t despair! Armed with the knowledge in this article, you’ll be able to diagnose the problem and get back to work in no time.

Stihl Chainsaw Starts Then Dies (5 Electronic Ignition Fixes)