Why Did Stihl Discontinue The MS291? (5 Expert Insights)

Let’s face it, there’s a certain je ne sais quoi about the scent of freshly cut wood, the feel of a perfectly balanced chainsaw in your hands, and the satisfaction of splitting a clean stack of firewood. It’s a primal connection, a dance between man and nature, and it’s something I’ve been passionately involved in for over two decades. But even in this timeless craft, things change. Tools evolve, manufacturers shift strategies, and sometimes, our favorite workhorses are retired. That brings us to the elephant in the room: the Stihl MS 291. A solid, dependable saw for many, it’s no longer in production. But why? The question has sparked debates among seasoned loggers and weekend warriors alike.

In this guide, I’ll dissect the reasons behind the MS 291’s discontinuation, offering not just manufacturer’s explanations but also my own insights gleaned from years of hands-on experience. I’ll delve into potential replacements, explore the technical specifications that made the MS 291 a popular choice, and provide guidance on choosing the right chainsaw for your needs, whether you’re felling trees for profit or simply keeping your hearth warm through the winter.

Why Did Stihl Discontinue the MS 291? (5 Expert Insights)

The Stihl MS 291 was a staple for many, a mid-range chainsaw that struck a balance between power, weight, and affordability. Its departure from the market, however, wasn’t a sudden, inexplicable event. Several factors contributed to its discontinuation, and understanding these reasons is key to appreciating the current chainsaw landscape.

1. Emission Standards and Technological Advancements

The primary driver behind the MS 291’s discontinuation, in my opinion, is the ever-tightening grip of emission regulations. Governments worldwide are cracking down on pollutants, and small engines, like those in chainsaws, are under intense scrutiny.

The Challenge: Meeting stringent emission standards requires significant investment in engine technology. Two-stroke engines, traditionally used in chainsaws due to their power-to-weight ratio, are notoriously difficult to make compliant without sacrificing performance or increasing complexity (and therefore, cost).
Stihl’s Response: Stihl, like other manufacturers, is investing heavily in stratified scavenging engines and fuel injection systems to reduce emissions. However, retrofitting these technologies onto existing models like the MS 291 can be cost-prohibitive.
The MS 291’s Fate: Rather than significantly re-engineer the MS 291 to meet the latest emission standards, Stihl likely made the strategic decision to focus resources on newer models designed from the ground up to be cleaner and more efficient. This aligns with their long-term strategy of developing cutting-edge, eco-friendly equipment.
Data Point: The EPA Phase 3 emission standards for small non-road engines, implemented in stages between 2011 and 2019, significantly reduced allowable hydrocarbon (HC) and nitrogen oxide (NOx) emissions. Meeting these standards required substantial technological changes.

2. Market Demand and Product Line Optimization

The chainsaw market is dynamic. Consumer preferences shift, new technologies emerge, and manufacturers constantly adjust their product lines to meet evolving demands.

The Shift: The market is trending towards lighter, more powerful, and more technologically advanced chainsaws. Users are increasingly willing to pay a premium for features like electronic fuel injection, anti-vibration systems, and improved ergonomics.
Stihl’s Strategy: Stihl continually evaluates its product portfolio to identify redundancies and opportunities for optimization. If a model’s sales begin to plateau or decline due to competition from newer models or changing consumer preferences, it may be discontinued.
The MS 291’s Position: While the MS 291 remained a solid performer, it likely faced increased competition from Stihl’s own newer models, as well as offerings from other manufacturers. Its feature set, while adequate, may have been perceived as less compelling compared to more technologically advanced options.
Personal Experience: I’ve noticed a significant increase in demand for battery-powered chainsaws in recent years, especially among homeowners and occasional users. This trend is undoubtedly influencing manufacturers’ product development strategies.

3. Production Costs and Profit Margins

Manufacturing costs play a crucial role in any business decision, and chainsaw production is no exception.

The Equation: The cost of materials, labor, and manufacturing processes all contribute to the final price of a chainsaw. If production costs increase while the selling price remains relatively constant, profit margins can shrink.
The MS 291’s Economics: As the MS 291 aged, the cost of manufacturing certain components may have increased due to factors like obsolescence of tooling or rising material prices. If the chainsaw’s selling price couldn’t be raised proportionally without impacting sales, it may have become less profitable to produce.
Stihl’s Calculation: Stihl likely conducted a thorough cost-benefit analysis, weighing the cost of continuing to produce the MS 291 against the potential revenue and profit. If the analysis indicated that discontinuing the model would improve overall profitability, it would have been a logical decision.
Insight: Manufacturers often face a trade-off between maintaining a wide product range and focusing on models with higher profit margins. Streamlining the product line can lead to economies of scale and improved efficiency.

4. Parts Availability and Serviceability

Maintaining a chainsaw requires regular maintenance and occasional repairs. Ensuring the availability of spare parts is crucial for customer satisfaction and brand loyalty.

The Challenge: As chainsaws age, it becomes increasingly difficult and expensive to manufacture and stock spare parts. Obsolete tooling, dwindling demand, and the cost of warehousing all contribute to this challenge.
The MS 291’s Situation: While Stihl typically maintains parts availability for its products for many years, eventually, it becomes unsustainable to continue producing parts for older models. Discontinuing the MS 291 likely simplified Stihl’s parts management and reduced the risk of customers facing difficulties in obtaining replacement parts.
Stihl’s Commitment: Stihl is committed to providing service and support for its products, even after they are discontinued. However, discontinuing a model allows the company to focus its resources on supporting its current product line.
Recommendation: Before purchasing any chainsaw, it’s essential to inquire about parts availability and service support. A reliable parts network is crucial for ensuring the longevity of your investment.

5. The Rise of the MS 291’s Successors: MS 271 Farm Boss and MS 272

The MS 291 didn’t just vanish into thin air; its legacy lived on, arguably improved, in its successors. The MS 271 Farm Boss and the newer MS 272 represent Stihl’s evolution in this class of chainsaw.

The MS 271 Farm Boss: This model, in many ways, became the spiritual successor to the MS 291. It offers comparable power and performance, but with updated engine technology designed to meet stricter emission standards. While some argue the MS 291 had a slightly more robust feel, the MS 271 provided a more environmentally friendly alternative.
The MS 272: The MS 272 is designed with professionals in mind, boasting increased power, improved ergonomics, and advanced features like the M-Tronic engine management system. It directly addresses some critiques of the MS 291, such as its weight and vibration levels.
Technical Comparison:
- MS 291: Engine Displacement: 55.5 cc, Power Output: 3.8 bhp, Weight: 12.3 lbs (powerhead)
- MS 271 Farm Boss: Engine Displacement: 50.2 cc, Power Output: 3.5 bhp, Weight: 12.3 lbs (powerhead)
- MS 272: Engine Displacement: 50.2 cc, Power Output: 3.9 bhp, Weight: 12.1 lbs (powerhead)
My Take: While the MS 271 may have a slightly smaller engine displacement, the advancements in engine technology mean that it delivers comparable performance to the MS 291 while meeting stricter emission standards. The MS 272 offers a notable upgrade in power and features for those willing to invest a bit more.

Choosing the Right Chainsaw: A Practical Guide

The discontinuation of the MS 291 might leave some users feeling adrift, but the chainsaw market is teeming with excellent alternatives. The key is to identify your specific needs and choose a saw that matches your requirements.

1. Assess Your Needs

Before diving into specific models, take a moment to honestly assess your chainsaw needs. Ask yourself the following questions:

What types of tasks will you be performing? (e.g., felling trees, limbing, bucking firewood, pruning)
How frequently will you be using the chainsaw? (e.g., daily, weekly, monthly, occasionally)
What size of trees will you be cutting? (e.g., small branches, medium-sized trees, large-diameter logs)
What is your budget? (Chainsaw prices can range from a few hundred dollars to well over a thousand.)
Do you have any physical limitations? (Weight, vibration, and ergonomics are important considerations.)
Are there any noise restrictions in your area? (Battery-powered chainsaws are significantly quieter than gas-powered models.)

2. Chainsaw Types: A Quick Overview

Chainsaws can be broadly categorized into three main types:

Gas-Powered Chainsaws: These are the workhorses of the chainsaw world, offering the most power and versatility. They are ideal for demanding tasks like felling large trees and bucking firewood.
- Pros: High power, long run time, suitable for heavy-duty tasks
- Cons: Noisy, require fuel mixing, higher maintenance, heavier than other types
Battery-Powered Chainsaws: These are gaining popularity due to their convenience, low noise levels, and ease of use. They are well-suited for lighter tasks like pruning, limbing, and occasional firewood cutting.
- Pros: Quiet, no fuel mixing, low maintenance, lightweight
- Cons: Limited run time, lower power compared to gas-powered models, battery charging required
Electric Chainsaws (Corded): These offer a good balance of power and convenience, but their range is limited by the length of the power cord. They are suitable for tasks around the home where access to electricity is readily available.
- Pros: Consistent power, no fuel mixing, low maintenance
- Cons: Limited range, require access to electricity, cord can be cumbersome

3. Key Features to Consider

When evaluating different chainsaw models, pay attention to the following key features:

Engine Size/Motor Power: This determines the chainsaw’s cutting power. Larger engines (for gas-powered models) and higher voltage (for battery-powered models) generally provide more power.
Bar Length: The bar length should be appropriate for the size of trees you’ll be cutting. A longer bar allows you to cut larger diameter logs, but it also adds weight and can make the chainsaw more difficult to maneuver.
- Rule of Thumb: Choose a bar length that is at least two inches longer than the diameter of the largest tree you expect to cut.
Weight: A lighter chainsaw is easier to handle and reduces fatigue, especially during prolonged use.
Anti-Vibration System: This reduces the amount of vibration transmitted to your hands and arms, improving comfort and reducing the risk of vibration-related injuries.
- Data Point: Prolonged exposure to chainsaw vibration can lead to Hand-Arm Vibration Syndrome (HAVS), a debilitating condition that affects blood vessels, nerves, and joints.
Chain Brake: This is a critical safety feature that stops the chain immediately if kickback occurs.
Chain Tensioning System: A tool-less chain tensioning system makes it easier to adjust the chain tension, which is essential for safe and efficient operation.
Automatic Oiler: This lubricates the chain and bar, reducing friction and extending their lifespan.
Ergonomics: Look for a chainsaw with a comfortable grip and well-balanced design.
Fuel Capacity/Battery Life: Consider the fuel capacity (for gas-powered models) or battery life (for battery-powered models) to ensure you can complete your tasks without frequent refueling or recharging.
- Tip: Carry extra fuel or spare batteries to avoid interruptions.

4. Exploring Alternatives to the MS 291

Given the MS 291’s discontinuation, here are some excellent alternatives to consider:

Stihl MS 271 Farm Boss: As mentioned earlier, this is a natural successor to the MS 291, offering comparable performance with improved emissions.
Stihl MS 272: A professional-grade option with increased power and advanced features.
Husqvarna 455 Rancher: A popular and reliable chainsaw with a good balance of power and features.
Husqvarna 460 Rancher: A slightly more powerful option than the 455, suitable for larger trees.
Echo CS-590 Timber Wolf: A powerful and durable chainsaw with a reputation for reliability.
Milwaukee M18 FUEL Chainsaw: A high-performance battery-powered chainsaw that rivals the power of some gas-powered models.

5. Safety First: Essential Protective Gear

Operating a chainsaw is inherently dangerous, so it’s crucial to wear appropriate protective gear at all times.

Helmet: Protects your head from falling branches and debris. Choose a helmet that meets ANSI Z89.1 standards.
Eye Protection: Safety glasses or a face shield protect your eyes from flying wood chips and debris.
Hearing Protection: Chainsaws are loud, so wear earplugs or earmuffs to protect your hearing.
- Data Point: Prolonged exposure to noise levels above 85 decibels can cause permanent hearing damage. Chainsaws typically produce noise levels between 100 and 115 decibels.
Gloves: Protect your hands from cuts, abrasions, and vibration. Choose gloves that provide a good grip and fit comfortably.
Chainsaw Chaps or Pants: These are made of ballistic nylon or other cut-resistant materials and protect your legs from chainsaw injuries.
Steel-Toed Boots: Protect your feet from falling logs and chainsaw injuries.

Wood Processing: From Tree to Firewood

Once you’ve chosen the right chainsaw and equipped yourself with the necessary safety gear, it’s time to get to work. Wood processing involves several steps, from felling the tree to splitting and stacking the firewood.

1. Felling Techniques

Felling a tree is a complex and potentially dangerous task that requires careful planning and execution.

Assess the Tree: Before felling a tree, carefully assess its size, lean, and condition. Look for any signs of decay or weakness.
Plan the Fall: Determine the direction in which you want the tree to fall. Consider the tree’s natural lean, wind direction, and any obstacles in the area.
Clear the Area: Remove any obstacles from the area around the tree, including brush, rocks, and debris.
Establish Escape Routes: Plan two escape routes that are at a 45-degree angle away from the direction of the fall.
Make the Notch: Cut a notch on the side of the tree facing the direction of the fall. The notch should be about one-third of the tree’s diameter.
- Types of Notches: Open face notch, conventional notch, Humboldt notch. The open face notch is generally considered the safest and most accurate.
Make the Back Cut: Cut the back cut on the opposite side of the tree from the notch. Leave a hinge of wood between the back cut and the notch.
- Hinge Width: The hinge should be about 10% of the tree’s diameter.
Wedge the Tree (If Necessary): If the tree doesn’t start to fall on its own, use wedges to help guide it in the desired direction.
Retreat Along Your Escape Route: Once the tree starts to fall, retreat quickly and safely along your escape route.

2. Limbing and Bucking

Once the tree is on the ground, it’s time to limb and buck it into manageable sections.

Limbing: Remove the branches from the tree trunk. Start at the base of the tree and work your way up. Be careful to avoid kickback.
- Technique: Cut the branches from the underside, then finish the cut from the top. This prevents the branch from pinching the chainsaw bar.
Bucking: Cut the tree trunk into desired lengths. The length of the firewood will depend on the size of your fireplace or wood stove.
- Standard Firewood Length: 16 inches is a common length, but you may need to adjust it based on your specific needs.
Log Diameter: A log diameter of 6-12 inches is generally considered ideal for firewood. Larger logs can be more difficult to split and season.

3. Splitting Firewood

Splitting firewood can be done manually with an axe or maul, or with a hydraulic log splitter.

Manual Splitting:
- Axe: A splitting axe is designed for splitting smaller logs.
- Maul: A splitting maul is heavier than an axe and is better suited for splitting larger logs.
- Safety: Always wear safety glasses and gloves when splitting firewood.
- Technique: Position the log on a solid surface, such as a chopping block. Stand with your feet shoulder-width apart and swing the axe or maul with a controlled motion.
Hydraulic Log Splitter:
- Types: Electric, gas-powered, and hydraulic.
- Tonnage: Choose a log splitter with sufficient tonnage for the size of logs you’ll be splitting. A 20-ton log splitter is generally sufficient for most firewood applications.
- Safety: Always wear safety glasses and gloves when operating a log splitter.
- Technique: Place the log on the log splitter and activate the ram. Be sure to keep your hands clear of the splitting area.

4. Seasoning Firewood

Seasoning firewood is essential for reducing its moisture content and making it burn efficiently.

Moisture Content: Freshly cut wood can have a moisture content of 50% or higher. Seasoned firewood should have a moisture content of 20% or less.
Drying Time: The drying time will depend on the type of wood, the climate, and the stacking method. Generally, firewood should be seasoned for at least six months, and preferably for a year or more.
- Hardwoods vs. Softwoods: Hardwoods like oak and maple typically take longer to season than softwoods like pine and fir.
Stacking Method: Stack the firewood in a single row, off the ground, and under cover. This will allow for good air circulation and prevent the wood from rotting.
- Air Circulation: Ensure there is at least 6 inches of space between rows of firewood.
Wood Moisture Meter: Use a wood moisture meter to check the moisture content of the firewood before burning it.
- Target Moisture Content: Aim for a moisture content of 15-20% for optimal burning.
Data Point: Burning unseasoned firewood can lead to creosote buildup in your chimney, which can increase the risk of chimney fires.

Technical Specifications: A Deeper Dive

Understanding the technical specifications of wood processing is crucial for ensuring safety, efficiency, and quality.

1. Wood Selection Criteria

Choosing the right type of wood for firewood is important for achieving optimal burning characteristics.

Hardwoods: These are generally preferred for firewood due to their high density and long burning time. Examples include oak, maple, ash, and birch.
- BTU Content: Hardwoods typically have a higher BTU (British Thermal Unit) content per cord than softwoods.
- Oak: Approximately 24-29 million BTU per cord.
- Maple: Approximately 20-25 million BTU per cord.
Softwoods: These burn quickly and produce less heat than hardwoods. They are best suited for kindling or starting fires. Examples include pine, fir, and spruce.
- BTU Content: Softwoods typically have a lower BTU content per cord than hardwoods.
- Pine: Approximately 15-20 million BTU per cord.
Avoid: Avoid burning treated wood, painted wood, or wood that has been exposed to chemicals. These materials can release harmful toxins into the air.
Wood Density: Denser woods generally burn longer and produce more heat.
Bark Content: Woods with high bark content tend to burn less efficiently.

2. Tool Calibration Standards

Maintaining your chainsaw and other wood processing tools is essential for safety and performance.

Chainsaw Chain Sharpening: A sharp chain is crucial for efficient cutting and reducing the risk of kickback. Sharpen the chain regularly using a chainsaw file or a chain grinder.
- Filing Angle: Maintain the correct filing angle for your chain type. Typically, this is around 30 degrees.
Chainsaw Bar Maintenance: Clean the chainsaw bar regularly and check for wear and tear. Replace the bar if it is damaged or worn.
Chainsaw Carburetor Adjustment: Adjust the carburetor to ensure the engine is running smoothly and efficiently. Refer to the chainsaw’s owner’s manual for instructions.
Log Splitter Maintenance: Regularly check the hydraulic fluid level and lubricate the moving parts.
Axe and Maul Maintenance: Keep the axe and maul sharp and free of rust.
Calibration Frequency: Chainsaws used professionally should be calibrated more frequently than those used for occasional home use.
Technical Requirement: Chainsaw chains should be sharpened when they exhibit signs of dullness, such as producing fine sawdust instead of chips or requiring excessive force to cut.

3. Safety Equipment Requirements

Using the correct safety equipment is paramount when working with chainsaws and processing wood.

Helmet: Must meet ANSI Z89.1 standards and be properly fitted.
Eye Protection: Safety glasses or a face shield must meet ANSI Z87.1 standards.
Hearing Protection: Earplugs or earmuffs must provide a Noise Reduction Rating (NRR) of at least 20 decibels.
Gloves: Should be durable and provide a good grip. Leather gloves are a good choice.
Chainsaw Chaps or Pants: Must meet ASTM F1897 standards and provide adequate protection for the legs.
Steel-Toed Boots: Must meet ASTM F2413 standards and provide protection for the feet.
First Aid Kit: Should be readily available and contain essential supplies for treating cuts, burns, and other injuries.
Emergency Communication: Ensure you have a way to communicate in case of an emergency, such as a cell phone or a two-way radio.
Requirement: All safety equipment should be inspected regularly for damage and replaced as needed.

Case Studies: Lessons from the Field

Over the years, I’ve encountered numerous challenges and learned valuable lessons while processing wood. Here are a few case studies that highlight the importance of technical knowledge and safety practices.

1. The Case of the Unseasoned Oak

The Scenario: A homeowner attempted to burn freshly cut oak firewood in their wood stove.
The Problem: The firewood was difficult to ignite, produced a lot of smoke, and burned inefficiently. Creosote buildup in the chimney was also a concern.
The Solution: The homeowner was advised to season the firewood for at least a year before burning it.
The Lesson: Seasoning firewood is crucial for efficient burning and reducing the risk of chimney fires.
Technical Detail: Oak firewood typically requires 12-18 months of seasoning to reach a moisture content of 20% or less.

2. The Case of the Dull Chain

The Scenario: A logger was struggling to fell a large tree with a chainsaw. The chain was cutting slowly and required excessive force.
The Problem: The chainsaw chain was dull and needed to be sharpened.
The Solution: The logger sharpened the chain using a chainsaw file.
The Lesson: A sharp chain is essential for efficient cutting and reducing the risk of kickback.
Technical Detail: A dull chain can increase the risk of kickback by as much as 50%.

3. The Case of the Improper Felling

The Scenario: A homeowner attempted to fell a tree without properly planning the fall.
The Problem: The tree fell in the wrong direction and damaged a nearby fence.
The Solution: The homeowner was advised to seek professional assistance for future tree felling projects.
The Lesson: Felling a tree is a complex task that requires careful planning and execution.
Technical Detail: The felling zone should be at least 1.5 times the height of the tree.

Conclusion: Mastering the Art of Wood Processing

The discontinuation of the Stihl MS 291 is a reminder that the chainsaw market is constantly evolving. However, the fundamental principles of wood processing remain the same. By understanding the technical specifications, following safety guidelines, and honing your skills, you can safely and efficiently transform trees into valuable resources like firewood. Whether you’re a seasoned logger or a weekend warrior, I hope this guide has provided you with the knowledge and insights you need to succeed in the art of wood processing. Now, get out there, respect the wood, and stay safe!