Why Are Pawls Breaking in Stihl Chainsaws?

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Updated in October 2025 | By John

Stihl Chainsaw Pawl Breakage Why It Happens and How to Prevent It

Stihl chainsaws are known for their power and durability, but even the best chainsaws can experience problems. One common issue is pawl breakage. In this blog post, we’ll discuss why pawls break on Stihl chainsaws and what you can do to prevent it from happening.

We’ll start by explaining what a pawl is and what it does. Then, we’ll discuss the different causes of pawl breakage and how to identify if your chainsaw’s pawl is broken. Finally, we’ll offer some tips on how to prevent pawl breakage in the future.

By the end of this blog post, you’ll have a better understanding of why pawls break on Stihl chainsaws and what you can do to keep your chainsaw running smoothly.

Why Do Pawls Keep Breaking In Stihl Chainsaws

Pawls on Stihl chainsaws break due to a number of factors, including:

Improper lubrication:

The pawls are a critical part of the chainsaw’s mechanism and need to be properly lubricated to function properly. If the chainsaw is not lubricated regularly, the pawls will wear out quickly and break.

Overloading the chainsaw:

The pawls are designed to engage and disengage the chain when it is under load. If the chainsaw is overloaded, the pawls will be forced to work harder than they are designed to and will break.

Improper maintenance:

The pawls are a relatively simple part, but they need to be properly maintained to function properly. If the pawls are not cleaned and adjusted regularly, they will wear out quickly and break.

By following these simple tips, you can help prevent pawls from breaking on your Stihl chainsaw:

Lubricate the chainsaw regularly:
Use a high-quality chainsaw oil and apply it to the pawls and other moving parts of the chainsaw.

Do not overload the chainsaw:
Use the chainsaw for tasks that are within its weight and power rating.

Maintain the chainsaw properly:
Clean and adjust the pawls regularly to ensure that they are working properly.

Why Do Pawls Keep Breaking in Stihl Chainsaws?

What is a Pawl?

A pawl is a small, spring-loaded lever that engages with a ratchet to prevent the chain from moving backward. It is located on the front of the chainsaw, just below the chain sprocket.

Why Do Pawls Break?

There are a few reasons why pawls can break in Stihl chainsaws.

Improper lubrication:

The pawl is a critical component of the chainsaw, and it needs to be properly lubricated to function properly. If the pawl is not lubricated, it will wear down faster and eventually break.

Overloading the chainsaw:

The pawl is designed to handle a certain amount of force. If you overload the chainsaw, the pawl can be damaged or broken.

Debris:

Debris can get caught in the pawl and cause it to malfunction. This can happen if you are cutting through branches with nails or other sharp objects.

Worn out pawls:

Pawls can wear out over time, just like any other part of the chainsaw. If the pawls are worn out, they will not be able to properly engage with the ratchet and the chain will be able to move backward.

How to Prevent Pawl Breakage

There are a few things you can do to prevent pawl breakage in your Stihl chainsaw.

Properly lubricate the chainsaw:

Make sure to lubricate the pawl regularly with a light oil. This will help to keep the pawl moving smoothly and prevent it from wearing down.

Avoid overloading the chainsaw:

Do not overload the chainsaw with more than it can handle. This will help to prevent the pawl from being damaged or broken.

Keep the chainsaw free of debris:

Make sure to keep the chainsaw free of debris, especially nails and other sharp objects. This will help to prevent debris from getting caught in the pawl and causing it to malfunction.

Replace worn out pawls:

If you think the pawls in your chainsaw are worn out, have them replaced by a qualified technician. This will help to ensure that the chainsaw is operating properly and that the pawls are not going to break.

What to Do If the Pawl Breaks

If the pawl in your Stihl chainsaw breaks, you will need to have it replaced. You can either do this yourself or have it done by a qualified technician. If you choose to do it yourself, you will need to purchase a replacement pawl and follow the instructions in the owner’s manual.

Here are the steps involved in replacing a pawl in a Stihl chainsaw:

1. Remove the chain cover.
2. Remove the old pawl.
3. Install the new pawl.
4. Reattach the chain cover.

Note:

It is important to make sure that the new pawl is properly lubricated before you install it. You can do this by applying a light coat of oil to the pawl.

Here are some tips for replacing a pawl in a Stihl chainsaw:

Be careful not to drop the pawl into the chainsaw housing. If you do, you will need to remove the chainsaw housing to retrieve it.
Make sure that the pawl is properly seated in the pawl groove. If it is not, the chain will not be able to move properly.
Tighten the pawl nut securely. If the nut is not tight enough, the pawl can come loose and cause the chain to move backward.

Also Read THis: Why Does Chainsaw Keep Stalling

FAQs

Why do pawls keep breaking in Stihl chainsaws?

There are a few reasons why pawls may keep breaking in Stihl chainsaws.

Improper lubrication: The pawl is a small metal part that engages with the chain brake to stop the chain from moving. If the pawl is not properly lubricated, it can become dry and brittle, which can lead to it breaking.

Overloading the chainsaw: The pawl is designed to engage with the chain brake when the chain is under heavy load. If the chainsaw is overloaded, the pawl can be forced to engage and disengage repeatedly, which can cause it to wear out prematurely.

Damaged pawl: The pawl can also be damaged if it comes into contact with foreign objects, such as rocks or nails. This can cause the pawl to become misshapen or damaged, which can prevent it from engaging properly with the chain brake.

How can I prevent pawls from breaking in my Stihl chainsaw?

There are a few things you can do to prevent pawls from breaking in your Stihl chainsaw.

Properly lubricate the pawl: Make sure to lubricate the pawl regularly with a light oil or grease. This will help to keep the pawl from becoming dry and brittle.

Don’t overload the chainsaw: Avoid overloading the chainsaw by only cutting wood that is within the chainsaw’s recommended cutting capacity.

Inspect the pawl regularly: Inspect the pawl regularly for signs of wear or damage. If the pawl is damaged, replace it immediately.

What are the symptoms of a broken pawl?

The following are some of the symptoms of a broken pawl:

The chain brake may not engage properly.
The chain may jump or run away when the brake is engaged.
The chainsaw may make a loud noise when the brake is engaged.

How do I fix a broken pawl?

If the pawl is broken, it will need to be replaced. To replace the pawl, you will need to follow the following steps:

1. Remove the chainsaw’s chain cover.
2. Locate the pawl and remove it from the chainsaw.
3. Install the new pawl in the chainsaw.
4. Reattach the chain cover.

How much does it cost to replace a pawl?

The cost of replacing a pawl will vary depending on the chainsaw model and the cost of the replacement pawl. However, you can expect to pay between $10 and $20 for a new pawl.

About The Author

Hi, I’m John, the creator of this site.
With years of hands-on gardening experience, I’m passionate about growing fresh fruits and vegetables and making gardening easy for everyone.
Here, I share tips, ideas, and inspiration to help you enjoy a thriving garden—no matter your skill level!