How to Reload a Stihl Weed Eater Head? Head-Specific Reload

Introduction

Running out of trimmer line mid-yard work is one of the most frustrating setbacks for any Stihl weed eater owner. Many people assume they need to replace the entire cutting head when this happens, but reloading the head yourself is a simple, cost-effective task that takes 5 to 10 minutes and requires no special tools. The exact process for How to Reload a Stihl Weed Eater Head? varies depending on the type of head your trimmer uses, as Stihl produces three main head designs for its consumer and professional lines. This guide covers head-specific reload steps for all common Stihl head types, plus tips to avoid jams, extend the life of your equipment, and keep your trimmer running smoothly all season long.

• Understanding Your Stihl Weed Eater Head Types
• Tools and Materials You’ll Need for Reloading
• Step-by-Step Guide to Reloading a Bump Feed Stihl Head
• Step-by-Step Guide to Reloading a Fixed Line Stihl Head
• How to Reload an Automatic Feed Stihl Weed Eater Head
• Head-Specific Reload Tips for Optimal Performance
• Common Mistakes to Avoid When Reloading Your Stihl Head
• Comparison Table: Stihl Head Type Reload Requirements
• Maintaining Your Stihl Weed Eater Head Between Reloads
• Frequently Asked Questions
• Conclusion

Understanding Your Stihl Weed Eater Head Types

Stihl uses three distinct head designs across its trimmer lineup, each with a unique reload process. Identifying which head you have is the first step to successfully answering the question How to Reload a Stihl Weed Eater Head? for your specific model. Below is a breakdown of each common head type:

Bump Feed Heads

Bump feed heads are the most widely used design for residential Stihl trimmers. They feature an internal spool that holds a continuous length of trimmer line, and advance more line when you bump the head lightly on the ground while the trimmer is running at full throttle. Models like the Stihl FS 38, FS 45, and most FSA series battery-powered trimmers come standard with bump feed heads.

Fixed Line Heads

Fixed line heads do not use a spool. Instead, they hold two pre-cut segments of trimmer line that are anchored directly to the head housing, with no feed mechanism required. These heads are most common on commercial-grade Stihl trimmers like the FS 90 R and FS 94 R, as they are more durable for heavy, daily use and never tangle.

Automatic Feed Heads

Automatic feed heads are a newer Stihl design that advances line automatically when you increase the throttle, eliminating the need to bump the head on the ground. They use an internal spool similar to bump feed heads, but have a small mechanical mechanism that feeds line as you work. These heads are found on newer FSA battery trimmers and select FS gas models, and are popular for their convenience.

Tools and Materials You’ll Need for Reloading

You don’t need any specialized tools to reload a Stihl weed eater head – most of the items you need are likely already in your garage. Gather the following before you start to make the process faster and safer:

• Replacement Stihl trimmer line (correct diameter for your head, usually .080″ or .095″ – check your owner’s manual for the exact specification)
• Work gloves (to protect your hands from sharp line edges)
• Safety glasses (to guard against flying debris or snapped line)
• Flathead screwdriver (for heads with a screw-on cover)
• Needle-nose pliers (to help pull line through tight spots)
• Trim line cutter or heavy-duty scissors (to cut line to the correct length)
• Small cleaning brush (to remove grass and debris from the head housing before reloading)

While Stihl’s OEM (original equipment manufacturer) line is recommended for optimal performance, high-quality aftermarket line that matches your head’s required diameter works just as well for most users.

Step-by-Step Guide to Reloading a Bump Feed Stihl Head

Bump feed heads are the most common Stihl design, so these steps apply to the majority of residential Stihl trimmers. Follow this process for a smooth, jam-free reload:

1. Disconnect the spark plug wire for safety: For gas-powered trimmers, pull the rubber boot off the spark plug to prevent accidental starting while you work. For battery trimmers, remove the battery pack entirely. This is a non-negotiable safety step that prevents serious injury.
2. Remove the trimmer head from the shaft: Most bump feed heads twist counterclockwise to release from the shaft’s locking mechanism. Some models have a small release tab you press before twisting. Set the head on a flat work surface once removed.
3. Empty the old line from the spool: Pull out any remaining line from the spool, then remove the spool from the head housing. Discard the old line, and use your cleaning brush to wipe out any grass, dirt, or debris from the inside of the head housing to prevent jams later.
4. Measure and cut your new trimmer line: Cut a single length of line between 10 and 15 feet long, depending on your head’s capacity (check your manual for the exact recommended length). Most bump feed heads use a single continuous line that loops inside the spool.
5. Wind the line onto the spool: Find the directional arrow on the top of the spool – this indicates the direction you should wind the line, almost always clockwise. Feed one end of the line into the small eyelet on the center of the spool, then wrap the line tightly and evenly around the spool, following the arrow direction. Avoid overlapping lines, as this will cause jams when feeding.
6. Leave line ends exposed: Once the spool is full, leave 6 to 8 inches of line sticking out of both ends of the spool. These ends will feed out through the head’s exit slots when you bump the head on the ground.
7. Reinsert the spool into the head housing: Place the wound spool back into the head, making sure the two line ends are aligned with the exit slots on the sides of the head. Some spools have small tabs that lock into place – make sure these are seated properly.
8. Reattach the head to the trimmer shaft: Align the head’s mounting hole with the shaft, twist clockwise until it locks into place. Give it a gentle tug to make sure it’s secure.
9. Reconnect power and test the feed: Reattach the spark plug wire or reinsert the battery. Turn on the trimmer, and bump the head lightly on the ground while the trimmer is running at full throttle. You should see 6 to 8 inches of line advance with each bump. If line doesn’t feed, double-check that the line ends are in the exit slots and the spool is wound in the correct direction.

Step-by-Step Guide to Reloading a Fixed Line Stihl Head

Fixed line heads are designed for heavy-duty use, and their reload process is even faster than bump feed heads since there is no spool to wind. These steps apply to all Stihl fixed line head models:

1. Disconnect power to the trimmer: Remove the spark plug wire or battery pack to prevent accidental startup while you work.
2. Remove the head cover: Most fixed line heads have a small plastic cover held on by 2 to 4 screws. Use your flathead screwdriver to remove the screws, then lift off the cover to access the line anchors.
3. Remove the old line segments: Pull the old line pieces out of the anchor holes on the head. If any line is stuck, use pliers to gently pull it free.
4. Cut new line segments to the correct length: Measure and cut two pieces of trimmer line to the length specified in your owner’s manual – usually between 8 and 12 inches, depending on your head size. Make sure both pieces are exactly the same length to ensure even cutting performance.
5. Insert the new line into the anchors: Feed one end of each line segment into the anchor holes on the head, pulling tight to secure it in place. Most fixed line heads have a small notch or groove to hold the line end, so make sure the line is seated fully in the anchor.
6. Reattach the head cover: Place the cover back over the head, align the screw holes, and tighten the screws securely. Don’t over-tighten, as this can crack the plastic cover.
7. Reconnect power and test: Reattach the spark plug wire or reinsert the battery, turn on the trimmer, and test the line to make sure both segments are secure and cut evenly.

How to Reload an Automatic Feed Stihl Weed Eater Head

Automatic feed heads combine the convenience of hands-free line advancement with a simple reload process similar to bump feed heads. Follow these steps to reload your Stihl automatic feed head:

1. Disconnect power: Remove the battery pack or spark plug wire to avoid accidental operation while you work.
2. Remove the head assembly: Twist the head counterclockwise to release it from the shaft, or press the release tab if your model has one. Set the head on a flat surface.
3. Remove the empty spool: Press the release button on the side of the head housing to pop out the spool. Empty any remaining line from the spool, and wipe out the housing to remove debris.
4. Wind the new line onto the spool: Cut a 10 to 12 foot length of line (check your manual for exact length). Feed one end into the spool’s center eyelet, then wind the line tightly around the spool in the direction of the arrow printed on the spool (almost always clockwise). Leave 6 inches of line sticking out of both ends of the spool.
5. Reinsert the spool into the housing: Align the spool’s tabs with the slots in the head housing, then push the spool in until it clicks into place. Make sure the line ends are positioned in the exit slots on the head.
6. Reattach the head to the shaft: Twist the head clockwise until it locks securely to the trimmer shaft.
7. Test the automatic feed: Reconnect power, turn on the trimmer, and run it at full throttle for 5 to 10 seconds. The line should advance automatically without needing to bump the head. If it doesn’t feed, check that the spool is wound correctly and the line ends are in the exit slots.

Head-Specific Reload Tips for Optimal Performance

Following these tips will reduce jams, extend the life of your line and head, and make reloading faster every time you need to top up line:

• Always use the correct line diameter for your head: Line that’s too thick will jam the feed mechanism, while line that’s too thin will slip and not advance properly. Check your owner’s manual for the exact size required – most Stihl residential heads use .080″ round line, while commercial models often use .095″.
• Wind the line tightly and evenly: Loose, overlapping layers of line will catch on the spool and cause jams when feeding. Wrap the line tightly, and avoid crossing lines over each other as you wind.
• Don’t overfill the spool: Leave a small gap between the wound line and the edge of the spool. Overfilling will cause the line to rub against the head housing, leading to premature wear and jams.
• Align line ends with exit slots: After winding, make sure both line ends are positioned directly in the head’s exit slots before reinserting the spool. Misaligned line is the most common cause of feed failures after reloading.
• Clean the head housing before every reload: Grass, dirt, and debris build up inside the head over time, which can jam the spool or block line from feeding. Use a small brush to wipe out the housing every time you reload.
• Use Stihl OEM line for best results: While aftermarket line works, Stihl’s proprietary line is designed to be more durable, resist fraying, and feed smoothly through their heads, reducing the number of reloads you need to do over time.

Common Mistakes to Avoid When Reloading Your Stihl Head

Even experienced Stihl users make these errors, which can lead to jams, damaged equipment, or even injury. Avoid these common pitfalls to make reloading as smooth as possible:

• Skipping the safety step of disconnecting power: Forgetting to remove the spark plug wire or battery can lead to accidental startup while your hands are near the cutting head, causing serious injury. Always disconnect power first, every time you reload.
• Winding the line in the wrong direction: Ignoring the directional arrow on the spool will cause the line to unwind itself when you try to feed it, leading to jams and a head that won’t advance line. Always follow the arrow printed on your spool.
• Using the wrong line size: Line that’s too thick or too thin will cause feed issues and poor cutting performance. Double-check your manual’s specification before buying replacement line to avoid wasted money and frustration.
• Overfilling the spool: Cramming as much line as possible onto the spool seems like a good way to reduce reload frequency, but it causes line to rub against the head housing, leading to fraying, jams, and premature spool wear. Leave a small gap at the edge of the spool.
• Not securing line ends in the exit slots: If the line ends are not fully seated in the head’s exit slots, they will get caught inside the housing when you try to feed line, causing a jam. Always double-check that both ends are properly aligned before reattaching the head.
• Skipping debris cleaning: Failing to clean out old grass and dirt from the head housing before reloading will introduce debris into the spool mechanism, leading to jams and poor feeding performance. Take 30 seconds to brush out the housing every time you reload.

Comparison Table: Stihl Head Type Reload Requirements

This table breaks down the key differences between the three common Stihl head types to help you understand which process applies to your trimmer, and what to expect when reloading:

Maintaining Your Stihl Weed Eater Head Between Reloads

Proper maintenance between reloads will extend the life of your head and reduce the number of jams you experience. Follow these simple steps to keep your head in top condition:

• After each use, wipe down the head with a dry cloth to remove grass, mud, and debris. This prevents buildup that can jam the spool or block line feed.
• Every 5 to 10 reloads, disassemble the head and lubricate the spool axle with a small amount of light machine oil. This keeps the spool spinning smoothly and reduces wear.
• Inspect the spool for cracks, chips, or warping every time you reload. A damaged spool will cause line to feed unevenly, and will need to be replaced to avoid further damage to the head.
• Store your trimmer in a dry, sheltered location when not in use. Moisture can cause the line to become brittle and fray, and can lead to rust on the head’s metal components.
• Before each use, pull a few inches of line out manually to check for fraying or weak spots. Replace the line early if you notice damage to avoid it snapping mid-use.

Frequently Asked Questions

How often should I reload my Stihl weed eater head?

The frequency of reloads depends on how often you use your trimmer and the type of head you have. Bump feed and fixed line heads typically need reloading every 1 to 2 weeks for average residential use (1 to 2 hours per week), while automatic feed heads may last 2 to 3 weeks under the same conditions. Commercial users (more than 5 hours per week) may need to reload every few days. Always reload when you have less than 2 inches of line left exposed to avoid running the spool dry, which can damage the feed mechanism.

What line size should I use for my Stihl head?

The correct line size depends on your specific head model. Most residential Stihl bump feed and automatic feed heads use .080″ round trimmer line, while commercial-grade fixed line and bump feed heads typically use .095″ line. You can find the exact specification in your owner’s manual, or printed on a sticker on the head housing itself. Using the wrong size will cause feed jams, poor cutting performance, and premature wear on the head.

Why is my line jamming after reloading?

Line jams after reloading are almost always caused by one of four issues: winding the line in the wrong direction, overfilling the spool, using the wrong line size, or failing to align the line ends with the exit slots. To fix a jam, disconnect power, remove the head, and take apart the spool to remove any tangled line. Clean out any debris from the housing, then reload the line following the correct steps for your head type, making sure to follow the directional arrow on the spool and leave a small gap between the line and the spool edge.

Can I use aftermarket trimmer line instead of Stihl OEM line?

Yes, you can use high-quality aftermarket trimmer line as long as it matches the exact diameter required for your head. Stihl OEM line is formulated to be more durable and resist fraying, but reputable aftermarket brands work just as well for most users. Avoid cheap, low-quality line, as it frays easily, causes more jams, and will require more frequent reloads.

Why does my head wobble after reloading?

Head wobble is almost always caused by the head not being tightened securely to the shaft. After reloading, twist the head clockwise until it locks into place, then give it a firm tug to make sure it’s fully seated. If the wobble persists, check that the shaft’s locking mechanism is not damaged, and that you have the correct head for your trimmer model. A loose head can damage the trimmer shaft and cause poor cutting performance, so tighten it immediately if you notice wobbling.

Conclusion

Reloading your Stihl weed eater head is a simple, cost-effective maintenance task that saves you from having to replace the entire head when you run out of line. The exact process for How to Reload a Stihl Weed Eater Head? depends on whether you have a bump feed, fixed line, or automatic feed head, but all three processes take less than 10 minutes with basic tools. By following the head-specific steps outlined in this guide, using the correct line size, and avoiding common mistakes like winding the line in the wrong direction or overfilling the spool, you can keep your trimmer running smoothly all season long. Regular maintenance between reloads will further extend the life of your head and reduce the number of jams you experience. Next time you run out of line, skip the hardware store trip for a new head, and reload your existing one in minutes.