STIHL Complete Bar and Chain Guide for Safe and Efficient Cutting
STIHL Complete Bar and Chain Guide for Safe and Efficient Cutting
A clear, practical summary of STIHL’s Bar & Chain guide with both metric and imperial units for easy matching, setup, and maintenance.
Quick navigation
- ANSI kickback basics
- Green vs yellow color codes
- OILOMATIC and Ematic lubrication
- Reading pitch, gauge, and chain codes
- PICCO, RAPID, DURO, and HEXA chain families
- Guide bar choices and safety notes
- Simple selection workflow
- Sharpening, tension, and break-in
- What to expect from a dealer
- FAQ
ANSI kickback basics
ANSI/OPEI B175.1-2012 describes performance, design, and labeling rules for chainsaws. For saws below 3.8 cu in (about 62 cm³), the setup must meet a 45-degree computed kickback limit and include two devices that reduce kickback risk, for example, a working chain brake and a low-kickback chain. For saws at 3.8 cu in (≈ 62 cm³) and above, at least one such device is required.
STIHL follows this standard with labeled powerheads, chain loop boxes, and bar wrappers. Instruction manuals and safety leaflets are part of the package. Dealers are instructed to review the labels with you, explain compatibility, and provide the correct manual.
Kickback control is a system. Bar shape, chain design, brake response, lubrication, chain tension, and your stance each affect the outcome. These features reduce risk. They do not remove it.
Green vs yellow color codes
Green, low-kickback
- Chains and bars are designed to reduce kickback risk.
- Recommended for all users and rental fleets.
- Powerheads under 3.8 cu in (≈ 62 cm³) carry a green warning label.
Yellow, higher kickback risk
- Intended for trained users with specialized needs.
- More aggressive cutter shapes or bar types.
- Powerheads at or above 3.8 cu in (≈ 62 cm³) show a green and yellow label.
Labels, color dots on bars, tie straps on chain reels, and chain loop boxes follow the same green or yellow system, so you always know what you are mounting.
OILOMATIC and Ematic lubrication
OILOMATIC drive links channel bar oil directly to the rivets. This reduces friction, wear, and oil consumption. Chains are pre-stretched to reduce initial elongation. Rivet holes are chamfered, and cutters are chromed. Filing guides are stamped on the depth gauges and cutter tops to make angle control easier.
The Ematic bar uses shaped oil ramps in the rails. When paired with the OILOMATIC chain, oil is delivered where it is needed most, which can reduce oil use by up to 50 percent.
Benefits in practice
- Less stretch during break-in for more stable tension.
- Smoother rivet movement and lower heating.
- Lower oil consumption without starving the tip.
Setup tips
- On adjustable oilers, set high flow during break-in.
- Run the new loop at partial throttle with no load for a few minutes, then re-tension.
- Confirm oil throw at the bar tip on a clean surface.
Reading pitch, gauge, and chain codes
Three specs must match the saw and bar, pitch, gauge, and drive link count. The marketing code then tells you the cutter style and any special pattern. Example, 61 PMM3 means 3/8 in PICCO pitch (9.53 mm), .043 in gauge (1.1 mm), PICCO Micro Mini, with a single-humped drive link that lowers kickback tendency.
| Spec | Common values | Where you see it |
|---|---|---|
| Pitch | 1/4 in (6.35 mm), .325 in (8.25 mm), 3/8 in (9.53 mm), 3/8 in PICCO (9.53 mm), .404 in (10.26 mm) | Stamped on the depth gauge and in the catalog. Must match the bar and drive sprocket. |
| Gauge | .043 in (1.1 mm), .050 in (1.3 mm), .058 in (1.5 mm), .063 in (1.6 mm), .080 in (2.0 mm, harvester) | Stamped on the drive link and on the bar tail. Must match bar groove. |
| Drive link count | Varies with bar length, for example, 16–36 in bars equal 40–90 cm | Engraved on the bar tail and listed in loop charts. Defines loop length. |
| Cutter style | Micro (RM, PM), Super full-chisel (RS, PS), Duro carbide (RD3, PD3), HEXA (RH) | Part of the marketing number and tables in the catalog. |
PICCO, RAPID, DURO, and HEXA chain families
PICCO, compact profile for light and battery saws
PM and PM3 provide smooth cutting and low vibration. PMM3 is a narrow-kerf for light bars. PS and PS3 add bite for faster cuts while keeping the compact form. PD3 is carbide-tipped for dirty wood and roots. These are common on small mounts and battery models with 1/4 in (6.35 mm) or 3/8 in PICCO (9.53 mm) pitch and .043 in (1.1 mm) or .050 in (1.3 mm) gauge.
RAPID, pro chains for full-size saws
RM is a low-vibration semi-chisel workhorse in .325 in (8.25 mm) and 3/8 in (9.53 mm) pitch. RM3 lowers kickback tendency with a single-humped drive link. RS is full-chisel for speed in clean wood. RS3 reduces kickback tendency while staying aggressive. Skip versions like RMF and RSF use more tie straps between cutters for better chip clearance on long bars such as 28–36 in (70–90 cm). RSK has a Klassic cutter shape for control and chip flow. RMX is a ripping grind field at 10 degrees for small mill work.
HEXA, faster filing with a hex-shaped file
RH introduces a six-sided cutter shape that pairs with a matching hex file, which helps speed up hand sharpening and keep a consistent edge. RH3 lowers kickback tendency. RHF is the full-skip layout for long bars. These are 3/8 in (9.53 mm) pitch in .050 in (1.3 mm) or .063 in (1.6 mm) gauge.
DURO, carbide-tipped chains for harsh jobs
RD3 and PD3 hold an edge up to ten times longer in abrasive conditions, such as treated wood or sand in bark. These require a formed diamond wheel for sharpening. RDR is a rescue-focused chain for emergency services on specified saws.
Low kickback options
Look for **green-coded** PM3, PS3, RM3, RS3, and several RD3 loops. Match them with green reduced kickback bars to lower risk further.
Higher performance, higher responsibility
Full-chisel, square-ground, and skip families such as RS, RSL, RSLF, and RSK deliver speed. They require training and a properly working brake.
Guide bar choices and safety notes
Green-labeled reduced kickback bars are designed to reduce kickback risk when paired with green low-kickback chains. Yellow bars support higher feed rates for trained users. All wrappers and bars feature matching color dots and labels, allowing you to confirm compatibility at a glance.
Do not mount a bow guide. The increased kickback area cancels the benefit of the low-kickback chain design.
Simple selection workflow
- Read the bar tail. Confirm pitch and gauge, for example, 3/8 in (9.53 mm) pitch and .050 in (1.3 mm) gauge, and note the drive link count required for the loop length. Typical bar lengths range from 16–36 in (40–90 cm).
- Match the sprocket. Pitch must match both the bar and the drive sprocket. If you switch from .325 in (8.25 mm) to 3/8 in (9.53 mm), you need the correct rim or spur.
- Choose the chain family. For general work with lower risk, start with PM3 or RM3 in the correct pitch and gauge. For speed in clean wood with pro handling, consider RS or RH if trained.
- Pick the bar type. If you are new, use a green reduced kickback bar. If you run long bars or skip patterns, follow the professional tables in the catalog and keep the brake in top condition.
- For powerheads below 3.8 cu in (≈ 62 cm³), use green reduced kickback bars and low-kickback chains to align with the ANSI acceptance criteria.
Sharpening, tension, and break-in
First hour on a new loop
- Set the oiler to a higher flow if adjustable.
- Run at partial throttle without load for a few minutes, then re-tension.
- Check the oil throw from the tip and verify that the oil inlet and bar groove are clear.
Sharpening basics
- Use the correct file or wheel. HEXA uses the six-sided hex file or a HEXA-shaped grinding wheel. Carbide requires a formed diamond wheel.
- Maintain the top plate angles and lower depth gauges when the cutter length shortens. If you skip depth gauges, you lose feed and must push harder. That increases fatigue.
- Flip the bar at each sharpening to even the rail wear. Clean the groove and oil ports.
Rotate parts for longer life
Use two chains in rotation on a new sprocket. This keeps wear balanced across the bar, chain, and sprocket, extending service life. Replace worn parts as a set when needed.
What to expect from a dealer
Dealers should assemble and adjust the saw, confirm the correct labels, provide the manual, explain kickback, push-back, and pull-in, and demonstrate a safe start and a chain brake test. For rentals, ask for a **green** bar and chain setup and a safety manual in the case.
FAQ
- What does green on the chain box or bar mean
- Green means low-kickback design. It is the safer match for most users. Use a green bar with a green chain for the best risk reduction.
- Does a chain brake stop kickback by itself
- No. A responsive brake reduces injury risk. You still need the correct stance, grip, and a sharp chain with the right depth gauge setting.
- What is the difference between PICCO and RAPID
- PICCO is a compact profile seen on small and battery saws. RAPID targets full-size saws with both semi-chisel and full-chisel options.
- What is HEXA
- A six-sided cutter shape that pairs with a hex file for faster, more consistent hand sharpening? Available with a reduced-kickback option.
- When should I use carbide
- Use carbide in abrasive or dirty conditions such as roots, treated lumber, or sandy bark. Plan on diamond wheel sharpening.
- Is skip chain only for long bars
- Skip helps chip clearance and chain speed on long bars. It is also useful in specific cutting conditions if the operator is trained.
