How to Change the End On a Stihl Chainsaw Bar

Many Stihl chainsaws operate with a sprocket on the nose of the guide bar. These tips connect to the body of the guide bar and allow for a greater chain speed. However, the tips of these bars undergo the most duress while operating and can become bent or damaged from the excessive forces. Replacing the entire bar can also be an expensive repair. To save money on guide bars, the operator can replace the end on a Stihl chain saw guide bar.

Leather work gloves
Combination bar tool
Hammer
Punch
Rag
Brush
Replacement Stihl bar tip
Guide bar rivets

Instructions

- 1
  Unscrew both bar nuts on the clutch side of the engine, using the wrench end of the combination bar tool. Lift off the bar cover and pull away the bar and chain. Separate the bar from the chain.
- 2
  Lay the bar on a flat workspace with the tip hanging off the end. Brace your arm or elbow over the length of the guide bar. Set the punch onto the tip of one of the rivets holding the tip to the bar. Drive the rivet out with the hammer and punch.
- 3
  Drive out all remaining rivets and pull the nose off the end of the bar. Clean out the tip area of the guide bar’s body, brushing and wiping away any sawdust and bar oil.
- 4
  Fit the replacement bar tip into the notch on the end of the guide bar’s body. Thread the first rivet into the hole, lining it up with the tip and the guide bar. Drive the rivet into the bar with the hammer.
- 5
  Drive all remaining rivets into the guide bar with the hammer. Press hard on the tip of the bar to ensure the tip and the bar are joined as one unit. If the tip wiggles or bends under pressure, re-drive the rivets until the tip is properly secured to the end of the bar.

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