Most operators look at the log. The expert looks at the ground. The waste product ejecting from your clutch cover is a real-time diagnostic stream telling you exactly what is happening inside the cut.
If you know how to read the chips, you can predict a failure before it happens.
1. Fine Dust (The Flour) If your saw is producing fine, powdery dust, stop immediately.
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The Diagnosis: The cutters are not severing the wood fiber; they are abrading it. This creates friction heat, which hardens the steel of the chain and tempers the bar rails (turning them blue).
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The Cause: Your chain is dull, or your depth gauges (rakers) are too high, preventing the tooth from taking a bite.
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The Fix: Sharpen immediately. Check raker height.
2. Long Ribbons (Noodles) If you are seeing long, stringy strands of wood, do not panic.
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The Context: This occurs when cutting with the grain (ripping) rather than across it.
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The Warning: These "noodles" can clog the clutch cover and wrap around the drive sprocket. Clear the discharge chute frequently to prevent heat buildup.
3. Scorched Chips If the chips are thick but have blackened edges, or if they smell like burnt toast.
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The Diagnosis: Extreme friction.
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The Cause: The chain is sharp, but the bar lubrication has failed.
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The Oil Test: Hold the bar tip 2 inches from a light-colored stump or piece of paper. Rev the saw. You must see a distinct line of oil spray off the tip. If you don't, check your oiler worm gear or pickup filter. Cutting dry Ironbark without oil will destroy a bar in minutes.
4. The Square Chip The goal. When the chain is sharp and the rakers are set to 0.025", the waste should be uniform, square flakes. This indicates the wood is being sliced cleanly, the engine is under optimal load, and the heat is being ejected with the chip rather than soaked into the bar.