Step‑by‑Step: Reassemble Your Stihl Pole Saw Safely and Confidently

Stihl pole saws are celebrated for their reliability and precision. If you’ve taken your unit apart for maintenance, follow this expert guide to reassemble it correctly and ensure peak performance.

Quick reference: 10 essential steps for a flawless reassembly.

1. Attach the main shaft and liner to the motor housing tube.
2. Install the springs and bushings.
3. Insert the main shaft into the main pole.
4. Insert the inner extension tube and liner into the outer extension pole.
5. Insert the outer extension pole into the main pole.
6. Insert the white bushing into the main pole.
7. Secure the motor housing pole coupler in the main pole.
8. Secure the chain saw housing coupler in the main pole.
9. Attach the motor housing to the motor housing pole.
10. Attach the chain saw housing to the extension pole.

Reassembly Guide

Different Stihl models may feature varying numbers of bushings, springs, and couplers. The following steps apply broadly, but always refer to your specific model’s service manual.

1. Attach the Main Shaft and Liner to the Motor Housing Pole

Slide the motor housing liner into the motor housing pole. The main shaft—longest and featuring a splined body with a smooth end—should then be inserted fully, leaving the splined portion exposed while the smooth end is concealed inside the pole.

2. Install Springs and Bushings

Insert the circular metal bushings in the correct orientation, ensuring the opening faces the motor housing end. Place the springs between the bushings, allowing them to expand and contract smoothly during operation.

3. Insert the Main Shaft into the Main Pole

With the motor housing tube attached to the shaft, slide the shaft into the main pole. A white bushing should seal the shaft against the pole’s mouth; use a hammer to secure it flush. Verify that the grooves on the bushings align with the indentations inside the pole for optimal fit.

4. Insert Inner Extension Tube and Liner into Outer Extension Pole

Slide the inner extension tube into its liner, then insert both into the outer extension pole. Match the grooves on the follower with the pole’s internal indentations.

5. Insert the Extension Pole into the Main Pole

Align the splined shaft of the main pole with the splined tube inside the outer extension pole. Slide the extension pole in until the black bearing is flush against the motor housing pole.

6. Insert the White Bushing into the Main Pole

Slide the detached white bushing through the exposed part of the extension pole to the main pole’s mouth, hammering it into place.

7. Secure the Motor Housing Coupler

Slide the black coupler onto the motor housing pole, tighten the screws that were loosened during disassembly.

8. Secure the Chain Saw Housing Coupler

Insert the chain saw housing coupler onto the opposite end of the main pole, tightening the corresponding screws.

9. Attach the Motor Housing to the Motor Housing Pole

Insert the trigger handle first, then slide the motor housing into the pole. Tighten all previously loosened screws.

10. Attach the Chain Saw Housing to the Extension Pole

Secure the chain saw housing to the exposed end of the extension pole and re‑tighten all screws. For a visual walkthrough, see the video below.

Watch the reassembly video

Storage Tips

Proper storage protects your pole saw and prolongs its lifespan.

• Disconnect the power source.
• Clean debris from the chain housing and handle.
• Loosen the oil cap to relieve internal pressure.
• Secure the scabbard and store in a dry, child‑safe location.
• For extended storage, empty the oil tank and lubricate the chain before re‑scabbarding.

Click here to view a Stihl scabbard on Amazon.

Starting Your Stihl Pole Saw

• Check the fuel: Push the fuel pump bulb; fuel should rise if adequate.
• Start the engine: Use a cold start for unused units, or a warm start if the motor is still warm.
• Pull the starter rope: Pull until the engine rumbles, then verify operation by triggering the throttle a few times.

Wrap‑Up

Reassembling your Stihl pole saw correctly prevents operational issues and ensures safety. Refer to this guide whenever you perform maintenance, and store your unit properly for longevity.

For related tips, see: How to Trim a Palm Tree in 5 Simple Steps | How to Start a Stihl Chainsaw Without Flooding It?

Written by Uyan Santos – a freelance writer with expertise in research, illustration, design, and filmmaking. Uyan’s passion for writing brings fresh, engaging content to gardening and outdoor gear.

Editorial oversight by Steve Snedeker, seasoned gardener with decades of landscaping experience.