6 Most Common STIHL BR 800 Problems And Effective Fixes

STHIL BR 800 is a high-end gas-powered blower with high-quality and handy features. Unfortunately, according to most users, this backpack blower is prone to several malfunctions. The most common STIHL BR 800 problems are starting issues, poor performance, throttle complications, starter rope problems, excess vibrations, and leaking.

Are you thinking of purchasing the BR 800 blower? Read on as we dissect this blower’s issues and how to troubleshoot them

Starting Issues

STIHL BR 800 blowers might face starting issues due to the following:

  • Cold fuel
  • Clogged carburetors
  • Plugged valves
  • Leaking
  • Clogged lugs
  • Faulty chokes
  • Dirty blades
  • Damaged spark plugs

Cold fuel doesn’t flow smoothly. This restricts the fuel from reaching the engine, resulting in difficult starts. Always warm up the motor for three minutes before starting the blower.

The wrong fuel damages the engine’s internal parts, leading to malfunctions. Stick to the right STIHL BR 800 fuel mixture to increase your blower’s lifespan and have fuss-free starts.

Clogged and dirty carburetors contaminate the fuel. Dirty fuel blocks the fuel lines, reducing the engine’s fuel supply. This causes the engine to strain and have a problematic start. Regularly clean your blower’s carburetor to curb these issues.

Plugged valves block the fuel flow to the carburetor. Regularly monitor these blower components and clean them to avoid clogging. Regular STIHL BR 800 valve adjustment is crucial to prevent these issues.

STIHL BR 800 fuel systems are prone to leaking from time to time. Faulty hoses are the leading cause of this issue. Replace damaged hoses to solve these complications.

Dirty cable lugs on the blower’s wiring harness restrict smooth electric flow through the blowers system. Regularly clean these parts.

A faulty carburetor choke allows excess fuel to overflow the engine’s combustion area, leading to hard starts. Chokes wear out and malfunction with age. Monitor these blower elements closely and replace them at first sight of wearing out.

Dirt destroys the motor blades, leading to engine difficulties. Always clean your blower after operations to avoid these issues. Ensure you remove all the waste and wet leaves for the best outcome. 

Spark plugs are responsible for igniting the fuel and air mixture in the engine. This process starts the engine and keeps the blower running. When faulty, the engine has a hard time turning on. Replace damaged spark plugs with new ones.

Poor Performance

A reduction in the STIHL BR 800 blower performance results from:

  • Lack of regular maintenance
  • Clogged components
  • Damaged pistons

Dirt and debris buildup affects major blower parts, like the carburetor, leading to severe malfunctions. Keep a regular maintenance schedule to keep your blower in tip-top condition.

Sufficient air is crucial for complete combustion and maximum power production. A clogged air filter restricts air from reaching the engine, reducing its effectiveness. Regularly clean your blower’s air filter to solve these STIHL BR 800 problems.

You should clean all the air inlets, as they risk clogging from debris and dirt buildup. Carbonized spark arrestors, mufflers, and cylinder exhaust ports stress the blower’s engine. Replace these components with new ones immediately after they start carbonizing to prevent the problem from escalating.

Faulty pistons change their shape and alter the sealed area between the piston and cylinder. This allows oil to sip onto the pistons, reducing their effectiveness. These parts mostly get defective from prolonged use. Monitor them closely and replace them when they start to age.

Throttle Problems

STIHL BR’s throttle handle is prone to loosening with time. The handles have weak screws that loosen quickly. Regularly monitor the throttle handle screws and tighten them using a screwdriver if loose to avoid strenuous and uncomfortable operations.

Be careful not to apply too much pressure when tightening the screws. As per the STIHL BR 800 service manual, excess pressure damages the screws, meaning you’ll have to replace them.

STIHL throttle cables wear out and get damaged fast. Most owners use these blowers for highly demanding and aggressive operations. Throttle cables often get snagged on shrubs and trees. This reduces their lifespans significantly. Closely check these parts and replace them with new ones for better performance.

Follow these steps when changing the throttle cable.

  • First, remove the cover and detach the cable from the blower’s loom.
  • Spray some lubricant on the new cable and feed or place it.
  • While holding or maintaining tension, place the cable on its side.
  • Tighten the cable and ensure the slack is adjusted correctly before putting the cover back.

Starter Rope Issues

STHIL BR 800 starter ropes may refuse to pull out all the way, get too loose, or jam entirely sometimes. According to the STIHL BR 800 service manual, the starter rope may refuse to pull far enough if the rewind spring’s tension is too high. Reducing the tension will solve these STIHL BR 800 problems.

If your blower’s starter rope pulls out freely with no resistance, chances are that the spring is fatigued or the pawls are damaged. Due to these blowers’ aggressive operations, the springs and spawls wear out fast.

Check the springs closely and replace them if damaged. You should also fit in new spawls immediately after they start showing aging signs.

Starter ropes may jam and refuse to pull out if the rewind spring is stuck. To fix this problem, apply a solvent-based standard degreaser on the rewind spring.

Ensure the solution doesn’t contain halogenated or chlorinated hydrocarbons to prevent damaging these components. Pulling the starter rope multiple times is advisable to restore normal action.

Excess Vibrations

STIHL BR 800 excessive vibrations result from loose recoil screws. Loose screws make the blower parts move freely, producing noise. The best way to solve this problem is to replace your blower’s recoil housing.

Broken valves may also produce noise, Check on these components and replace them if damaged. You should also check on the engine’s cover. It’s made of plastic and prone to breaking from excessive vibrations. Replace it with a new one.


Leaking is a notorious problem among STIHL BR 800 blowers. Your STIHL blower might leak due to the following:

  • Faulty primer bulbs
  • Damaged fuel tanks
  • Loose caps

Damaged primer bulbs let fuel sip onto the blower’s body instead of flowing into the carburetor. Replace damaged primer bulbs immediately to avoid accidents.

Fuel tanks wear out and crack after prolonged use. Check these components closely and repair or replace them when cracked.

Tank caps loosen with time and let out gas. Replace them with new ones to curb leaking for good. Also, check for faulty fuel lines and replace them immediately.

Are STIHL BR 800 Blowers Any Good?

Although STIHL blowers are prone to many drawbacks, the STIHL BR 800 specs are mind-blowing.

Thanks to its design, the STHIL BR 800 blower’s backpack is less exerting to the user, making it ideal for long operations. What’s more, it weighs only 23 lbs.

Featuring an airflow rate of 912 cubic feet per minute and a 239 MPH air speed, STIHL BR 800 blowers guarantee the best results.

With several speed settings, STIHL 800 blowers allow you to control the air output to meet your specific needs. The cruise control enables you to maintain the settings easily, allowing you to work without disturbances.

A fuel tank capacity of 67.6 fl. oz keeps you working for a long time with no refilling breaks. Additional springs between the starter ropes and crankshafts make these blowers’ starting mechanisms more reliable than other brands.

STIHL BR 800 problems aren’t a deal breaker. All equipment, regardless of its quality, is prone to malfunctions. Moreover, this post breaks down fixes for all the leading STIHL BR 800 issues.