Stihl Chainsaw Won't Stay Running: 5 Pro Fixes (For Log Splitters)

Stihl Chainsaw Won’t Stay Running: 5 Pro Fixes (For Log Splitters)

A chainsaw refusing to stay running is a common problem, and thankfully, often a fixable one. Before you start tearing things apart, remember safety first! Disconnect the spark plug wire and wear appropriate personal protective equipment (PPE). These fixes are applicable to many Stihl models, but always consult your owner’s manual for specific instructions.

1. Fuel System Issues: The Prime Suspect

More often than not, a chainsaw that won’t stay running has a fuel-related problem. Here’s a breakdown:

Old or Contaminated Fuel: This is the most common culprit. Modern gasoline degrades quickly, especially when mixed with oil for two-stroke engines. Ethanol in gasoline attracts moisture, leading to corrosion and gumming up the fuel system.
- The Fix: Drain the fuel tank completely. If the fuel looks cloudy, smells stale, or has visible debris, it’s definitely bad. Refill with fresh, high-quality fuel mixed with the correct ratio of two-stroke oil (usually 50:1, but check your manual). I always recommend using fuel stabilizer, especially if the chainsaw will sit unused for more than a few weeks. I’ve learned this the hard way after leaving my saw sitting over the summer and having to clean the carburetor in the fall.
- Cost Implications: Fuel costs vary widely. In the US, you can expect to pay anywhere from $3 to $5 per gallon for regular gasoline. High-quality two-stroke oil can cost $10-$20 per quart. Fuel stabilizer is relatively inexpensive, around $5-$10 per bottle. Factor these costs into your annual firewood budget. For example, if I use 10 gallons of fuel per year at $4/gallon and a $15 bottle of oil, my fuel costs are $40 (fuel) + $15 (oil) = $55. Adding stabilizer for $8 brings the total to $63.
Clogged Fuel Filter: The fuel filter prevents debris from entering the carburetor. Over time, it can become clogged with dirt, sawdust, and fuel residue.
- The Fix: Locate the fuel filter inside the fuel tank (usually attached to the fuel line). Remove it and inspect. If it’s dirty, try cleaning it with carburetor cleaner. If it’s severely clogged, replace it. Fuel filters are inexpensive.
- Cost Implications: A new fuel filter typically costs between $5 and $10. It’s a small price to pay to avoid carburetor problems. I replace mine annually as a preventative measure, especially during heavy use seasons.
Blocked Fuel Line: Fuel lines can crack, become brittle, or get clogged with debris.
- The Fix: Inspect the fuel lines for cracks or damage. If they’re cracked, replace them. Use compressed air to blow out any debris from the fuel lines.
- Cost Implications: Fuel lines are relatively inexpensive, typically costing between $5 and $15 per foot. Replacing them is a simple DIY task.
Carburetor Issues: The carburetor mixes fuel and air for combustion. It’s a complex component and can be affected by old fuel, dirt, and other contaminants.
- The Fix: Start by cleaning the carburetor. Use carburetor cleaner to spray out all the jets and passages. If the carburetor is severely gummed up, you may need to disassemble it and soak the parts in carburetor cleaner. Carburetor rebuild kits are available, but if you’re not comfortable working on small engine components, it’s best to take it to a qualified repair shop. Many Stihl chainsaws have adjustable carburetors. Consult your owner’s manual to adjust the high (H) and low (L) speed screws. Incorrect adjustment can lead to stalling and poor performance.
- Cost Implications: Carburetor cleaner costs around $5-$10 per can. Carburetor rebuild kits can range from $15 to $50, depending on the model. Labor costs for carburetor repair at a shop can range from $50 to $150. I once tried to save money by rebuilding a carburetor myself, but ended up spending more on parts and frustration than if I had just taken it to a professional. I now factor in potential repair costs into my annual chainsaw maintenance budget.
- Log Splitter Connection: Many log splitters, especially those with gasoline engines, also use carburetors. The same fuel-related issues that affect your chainsaw can also plague your log splitter. Be sure to use fresh fuel and maintain the fuel system on your log splitter as well.

2. Spark Plug Problems: The Ignition Key

The spark plug ignites the fuel-air mixture in the cylinder. A faulty spark plug can cause starting problems, misfires, and stalling.

The Fix: Remove the spark plug and inspect it. Look for cracks, carbon buildup, or a fouled electrode. Clean the spark plug with a wire brush or replace it. Check the spark gap using a feeler gauge and adjust as needed (refer to your owner’s manual for the correct gap). To test the spark plug, connect the spark plug wire and ground the spark plug against the engine block. Pull the starter cord. You should see a strong, blue spark. If the spark is weak or nonexistent, replace the spark plug.
Cost Implications: Spark plugs are relatively inexpensive, typically costing between $5 and $10. I keep a spare spark plug on hand for each of my chainsaws and log splitters.

3. Air Filter Woes: Breathing Easy

A clogged air filter restricts airflow to the engine, leading to a rich fuel mixture and stalling.

The Fix: Remove the air filter and inspect it. If it’s dirty, clean it with compressed air or warm, soapy water. Allow the air filter to dry completely before reinstalling it. If the air filter is damaged or excessively dirty, replace it. Some air filters are foam, while others are paper. Foam filters can be washed and reused, while paper filters should be replaced.
Cost Implications: Air filters typically cost between $5 and $20, depending on the type and model. I clean mine regularly and replace them annually, or more frequently if I’m working in dusty conditions.

4. Exhaust System Blockage: Letting Off Steam

A clogged exhaust system restricts the flow of exhaust gases, leading to reduced power and stalling.

The Fix: Inspect the spark arrestor screen (if equipped) for carbon buildup. Clean the screen with a wire brush. Remove the muffler and inspect the exhaust port for carbon buildup. Use a scraper or wire brush to remove any carbon deposits. Be careful not to damage the cylinder or piston.
Cost Implications: Spark arrestor screens are inexpensive to replace, typically costing a few dollars. Muffler replacement can be more expensive, ranging from $30 to $100, depending on the model. I clean my spark arrestor screen every few months to prevent clogging.

5. Loose Connections and Wiring: The Electrical Gremlins

Loose wires, corroded terminals, or a faulty ignition module can cause intermittent stalling.

The Fix: Inspect all wiring connections for tightness and corrosion. Clean any corroded terminals with a wire brush. Check the spark plug wire for damage. If you suspect a faulty ignition module, it’s best to take the chainsaw to a qualified repair shop for testing and replacement.
Cost Implications: Wire connectors and terminals are inexpensive to replace. Ignition modules can range from $30 to $100, depending on the model. Diagnosing electrical problems can be time-consuming, so labor costs at a repair shop can add up.

Firewood Preparation Costs and Budgeting: A Deep Dive

Now that we’ve addressed the mechanical issues, let’s dive into the financial side of firewood preparation. Understanding the costs involved is crucial for efficient budgeting and maximizing your return on investment (or, at least, minimizing your expenses!).

Variable Factors Affecting Firewood Costs

The cost of preparing firewood varies greatly depending on several factors:

Wood Type: Hardwoods like oak, maple, and ash provide more heat and burn longer than softwoods like pine and fir. However, hardwoods can be more difficult to split and season. The price of standing timber also varies by species.
Location Accessibility: If you’re harvesting your own wood, the accessibility of the woodlot will affect your labor and transportation costs. Remote locations may require specialized equipment and longer travel times.
Seasonality: The demand for firewood typically peaks in the fall and winter, driving up prices. Seasoning firewood takes time, so planning ahead is essential.
Labor: Are you doing all the work yourself, or are you hiring help? Labor costs can be a significant expense.
Equipment: Do you own your own chainsaw and log splitter, or are you renting them? Equipment costs can be substantial.

Breaking Down the Cost Components

Let’s break down the cost components of firewood preparation:

Timber Purchase or Harvesting Costs:
- Standing Timber: If you’re harvesting your own wood, you’ll need to purchase standing timber from a landowner. Timber prices vary depending on the species, quality, and location. I’ve seen prices range from $10 to $50 per cord for standing timber, but this can fluctuate widely. Contacting local forestry services or timber brokers is the best way to get accurate pricing information.
  - Data Point: According to the US Forest Service, the average stumpage price (price for standing timber) for hardwood sawtimber in the Northeast was around $40 per thousand board feet (MBF) in 2022. This translates to roughly $10-$20 per cord, but remember that this is just an average. Firewood quality timber is generally cheaper than sawtimber.
    - Permits: In some areas, you may need a permit to harvest timber. Check with your local authorities.
  - Cost Implication: Permit fees can range from a few dollars to several hundred dollars, depending on the location and the size of the harvest.
    - Purchased Firewood Logs: Alternatively, you can purchase firewood logs directly from a supplier. This eliminates the need for harvesting but may be more expensive.
  - Data Point: The average price for a cord of mixed hardwood firewood in the US ranges from $150 to $400, depending on the location and the season. Prices are typically higher in urban areas and during the winter months. I’ve personally seen prices as high as $500 per cord in some areas during peak demand.
  - Tool Costs:
    - Chainsaw: As we’ve already discussed, chainsaw maintenance and repair costs can add up. Budget for fuel, oil, spark plugs, air filters, and potential repairs.
  - Cost Implication: A high-quality chainsaw can cost anywhere from $300 to $1000 or more. Regular maintenance is essential to prolong its lifespan. I budget around $100 per year for chainsaw maintenance, but this can vary depending on usage.
    - Log Splitter: Log splitters can be manual, gas-powered, or electric. Manual splitters are the least expensive but require significant physical effort. Gas-powered splitters are the most powerful but also the most expensive. Electric splitters are a good compromise for smaller jobs.
  - Cost Implication: Manual log splitters can cost as little as $100. Electric splitters typically range from $300 to $800. Gas-powered splitters can cost anywhere from $800 to $3000 or more. Renting a log splitter is a good option if you only need it occasionally. Rental fees typically range from $50 to $100 per day. I bought a gas-powered log splitter several years ago, and while it was a significant investment, it has saved me a lot of time and back pain.
    - Other Tools: You’ll also need other tools like axes, wedges, mauls, and measuring tapes.
  - Cost Implication: These tools are relatively inexpensive, but they can add up. Budget around $50 to $100 for these miscellaneous tools.
  - Labor Costs:
    - Your Own Labor: Even if you’re doing the work yourself, it’s important to consider the value of your time. How much is your time worth per hour?
  - Cost Implication: This is a subjective calculation, but it’s important to be realistic. If you could be earning $20 per hour at your regular job, then every hour you spend preparing firewood is costing you $20 in lost income.
    - Hired Labor: If you’re hiring help, labor costs can be a significant expense.
  - Data Point: The average hourly wage for a general laborer in the US is around $15 to $25. Labor costs can be higher in some areas. I’ve hired help in the past for stacking firewood, and it definitely speeds up the process, but it also adds to the overall cost.
  - Transportation Costs:
    - Fuel: Transporting firewood requires fuel. Factor in the cost of gasoline or diesel.
  - Cost Implication: Fuel costs can vary depending on the distance you’re transporting the wood and the fuel efficiency of your vehicle.
    - Vehicle Maintenance: Hauling heavy loads can put a strain on your vehicle. Budget for potential repairs.
  - Cost Implication: Vehicle maintenance costs can be unpredictable, but it’s important to be prepared.

Industry Benchmarks and Statistical Data

Average Price per Cord of Firewood: As mentioned earlier, the average price for a cord of mixed hardwood firewood in the US ranges from $150 to $400.
Fuelwood Consumption: According to the Energy Information Administration (EIA), about 2% of US households use wood as their primary heating source.
Timber Prices: Timber prices fluctuate depending on market conditions. Stay informed by consulting with local forestry services or timber brokers.

Practical Tips for Cost Optimization and Budget Management

Buy in Bulk: Purchasing standing timber or firewood logs in bulk can often save you money.
Season Firewood Properly: Properly seasoned firewood burns more efficiently, reducing your overall consumption. Aim for at least six months of seasoning, preferably longer. I always try to have a year’s worth of firewood seasoned and ready to go.
Maintain Your Equipment: Regular maintenance will prolong the lifespan of your chainsaw and log splitter, reducing repair costs.
Shop Around: Compare prices from different firewood suppliers and timber brokers.
Consider Alternative Heating Sources: While firewood can be a cost-effective heating source, it’s not always the cheapest option. Consider alternative heating sources like natural gas or propane.
Use a Budgeting Spreadsheet: Track your expenses and income using a budgeting spreadsheet. This will help you identify areas where you can save money.

Relevant Calculations and Formulas

Calculating Volume of Logs: The volume of a log can be estimated using the Doyle Log Scale, the Scribner Log Scale, or the International 1/4-inch Log Scale. These scales provide an estimate of the board feet of lumber that can be sawn from a log. For firewood purposes, a rough estimate is usually sufficient.
Estimating Drying Time: The drying time for firewood depends on the wood species, the size of the pieces, and the climate. As a general rule, hardwoods take longer to dry than softwoods. Split wood dries faster than unsplit wood. A moisture meter can be used to measure the moisture content of firewood. Aim for a moisture content of 20% or less for optimal burning. I use a moisture meter religiously to ensure my firewood is properly seasoned.

Budgeting Case Study: My Personal Experience

Let me share a personal example to illustrate the budgeting process. I live in a rural area and heat my home primarily with a wood stove. Here’s a breakdown of my firewood preparation costs for the past year:

Standing Timber: I purchased standing timber for $20 per cord. I harvested 5 cords, so my timber cost was $100.
Fuel: I used 15 gallons of gasoline for my chainsaw and log splitter, at a cost of $4 per gallon, for a total of $60.
Oil: I used 1 quart of two-stroke oil, at a cost of $15.
Chainsaw Maintenance: I spent $30 on a new air filter and spark plug.
Log Splitter Maintenance: I spent $20 on an oil change for my log splitter.
Labor: I spent approximately 50 hours preparing the firewood. At a rate of $20 per hour, my labor cost was $1000.

My total cost for 5 cords of firewood was $100 (timber) + $60 (fuel) + $15 (oil) + $30 (chainsaw maintenance) + $20 (log splitter maintenance) + $1000 (labor) = $1225. This works out to $245 per cord.

However, I also have to factor in the cost of my chainsaw and log splitter. I purchased my chainsaw for $500 and my log splitter for $1500. Assuming a lifespan of 10 years for each, my annual depreciation cost is $50 for the chainsaw and $150 for the log splitter. This adds another $200 to my annual firewood cost, bringing the total to $1425, or $285 per cord.

While this may seem expensive, it’s still cheaper than buying firewood from a supplier in my area, which typically costs around $350 per cord. Plus, I enjoy the process of preparing my own firewood.

Actionable Takeaways and Next Steps

Assess Your Needs: How much firewood do you need to heat your home for the winter?
Evaluate Your Resources: Do you have access to standing timber? Do you own a chainsaw and log splitter?
Create a Budget: Use the information in this guide to create a detailed budget for your firewood preparation project.
Plan Ahead: Start preparing your firewood well in advance of the heating season.
Stay Safe: Always wear appropriate PPE and follow safety guidelines when operating chainsaws and log splitters.

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 be volatile, making it difficult to predict profitability.
Rising Fuel Costs: Fuel costs are a major expense for loggers and firewood suppliers.
Competition: The firewood market can be competitive, especially in areas with a large number of suppliers.
Regulations: Logging and firewood harvesting are subject to regulations, which can add to the cost of doing business.
Labor Shortages: Finding reliable labor can be a challenge.

Compelling Phrases That Drive Interest

“Unlock the secrets to a warm and affordable winter.”
“Master the art of firewood preparation and save money.”
“Transform your woodlot into a sustainable source of heat.”
“Conquer chainsaw problems and split wood like a pro.”
“Budget your way to a cozy and cost-effective heating season.”

Technical Terms Explained

Board Foot: A unit of measurement for lumber, equal to 144 cubic inches (12 inches x 12 inches x 1 inch).
Cord: A unit of measurement for firewood, equal to 128 cubic feet (4 feet x 4 feet x 8 feet).
Stumpage Price: The price for standing timber.
Moisture Content: The amount of water in wood, expressed as a percentage of the dry weight.

Final Thoughts

Preparing your own firewood can be a rewarding and cost-effective way to heat your home. By understanding the costs involved and following the tips in this guide, you can budget your way to a warm and cozy winter without breaking the bank. And if your Stihl chainsaw starts acting up, you’ll be ready to diagnose the problem and get back to splitting wood in no time! I hope this guide has provided you with the knowledge and confidence to tackle your next firewood project. Happy splitting!

Stihl Chainsaw Won’t Stay Running: 5 Pro Fixes (For Log Splitters)