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Reassemble Cylinder, Engine Housing, and External Components

21:10
31:13
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At 21:10 in

How to Rebuild a Chainsaw Engine

What happens here

After installing the new cylinder and piston, it's time to secure the cylinder to the engine block. Place the new head gasket (green one) onto the engine block, aligning it correctly. Carefully lower the new cylinder assembly onto the engine block, ensuring the piston aligns properly. Torque the four cylinder bolts to the specified 12.6 foot-pounds using a torque wrench with a T27 bit. The video creator uses a special long Torx bit set for easier access. Once tightened, reinstall the compression release delete plug (if chosen) or the original compression release. Reattach the handle, exhaust system, throttle body assembly, air filter, and air filter cover, securing all components with their appropriate T27 bolts.

Goal: Secure the new cylinder and reattach all housing and external components.

Tools and materials

  • Long Torx Bit Set — Reaching cylinder bolts for proper torquing
  • New Compression Release Delete Plug — Either sealing the compression release port or reinstalling the valve
  • New Cylinder Stihl — Part of the main engine assembly
  • New Head Gasket — Sealing the cylinder to the engine block
  • Orange Rubber Gloves — Protecting hands
  • Stihl MS 500i Chainsaw — The chainsaw being reassembled
  • T27 Bit — Torquing T27 Torx head bolts
  • Torque Wrench — Applying precise torque to cylinder bolts