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Stihl 026 Chainsaw Service Repair Manual

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Stihl 026 Chainsaw Service Repair Manual
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  1. RA_U1_01_00.fm Seite 0 Dienstag, 13. Juli 2004 7:22 07 STIH) STIHL 024, 026 2004-08 Schwarz Prozeß 45,0° 120,0 LPI

  2. CONTENTS 1. Safety Precautions 1 6.2 6.2.1 6.2.2 6.3 Ignition Module Ignition Timing Removing and Installing35 Short Circuit Wire/ Ground Wire Wiring Harness Contact Spring Flywheel 34 35 12.5 12.5.1 12.5.2 Carburetor Leakage Testing Removing and Installing Adjusting Tank Vent Fuel Hose Tank Housing 60 60 2. Introduction 2 61 63 64 65 65 3. Specifications 3 36 37 38 38 12.5.3 12.6 12.7 12.8 6.4 6.5 6.6 3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.6 Engine Fuel System Ignition System Cutting Attachment Special Accessories For User For Service Tightening Torques 3 3 4 4 4 4 5 5 7. Rewind Starter 13. Special Servicing Tools and Aids 39 68 7.1 7.2 7.2.1 7.2.2 7.3 General Rewind Spring Replacing Tensioning Starter Rope/Starter Grip (ElastoStart) 39 39 39 40 13.1 Special Servicing Tools Servicing Aids 68 70 13.2 4. Clutch, Chain Drive, Chain Brake and Chain Tensioner 41 7 8. AV Handle System 1. SAFETY PRECAUTIONS 42 4.1 Clutch Drum and Chain Sprocket Clutch Chain Brake Checking Function Disassembling Assembling Anchor Pin for Brake Spring Pin for Hand Guard Front Chain Tensioner (024) Side Chain Tensioner 7 8 9 9 9 9. Master Control/ Handle System 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 43 If the engine is started up in the course of repairs or maintenance work, observe all local and country- specific safety regulations as well as the safety precautions and war- nings in the owner’s manual. 9.1 9.2 Switch Shaft Interlock Lever/ Throttle Trigger 43 11 43 10. Electric Handle Heating System 13 13 4.3.5 4.4 45 Gasoline is an extremely flamm- able fuel and can be explosive in certain conditions. 10.1 10.1.1 Troubleshooting Troubleshooting Chart Test Connections and Test Values Heater Switch Heating Element in Rear Handle Heating Element in Front Handle Generator 45 14 14 4.5 46 10.1.2 Improper handling may result in burns or other serious injuries. 5. Engine 15 47 48 5.1 Muffler/Spark Arresting Screen Catalytic Converter Construction and Function Leakage Test Preparations Pressure Test Vacuum Test Oil Seals Exposing the Cylinder Cylinder and Piston Removing Installing Piston Rings Crankcase Removing the Crankshaft Installing the Crankshaft Decompression Valve 10.2 10.3 15 16 Warning! Do not smoke or bring any fire or flame near the fuel. All work with fuel must be performed outdoors only. Spilled fuel must be wiped up immediately. 5.2 5.2.1 48 10.4 16 17 17 18 18 19 21 21 21 22 25 25 49 50 5.3 5.3.1 5.3.2 5.3.3 5.4 5.5 5.6 5.6.1 5.6.2 5.7 5.8 5.8.1 10.5 11. Chain Lubrication 52 Wash hands thoroughly after every contact with waste oil. 11.1 Pickup Body/ Suction Hose Valve Oil Pump Servicing 52 53 53 55 Do not pour waste oil down the drain or allow it to soak into the ground. 11.2 11.3 11.3.1 Collect waste oil and take it to an official disposal site for environ- ment-friendly disposal. 12. Fuel System 55 12.1 12.2 12.3 12.3.1 Air Filter/Choke Shutter 55 Carburetor Preheating Carburetor Heater Construction and Function Testing Troubleshooting Chart Printed Circuit Board 25 56 56 5.8.2 28 33 5.9 56 57 12.3.2 12.3.3 6. Ignition System 33 59 60 6.1 Spark Plug Boot/ Ignition Lead 12.4 33 © 1999 Andreas Stihl AG & Co., Waiblingen 024, 026 1

  3. 2. INTRODUCTION This service manual contains detailed descriptions of all the repair and servicing procedures specific to this power tool series. There are separate handbooks for servicing procedures for standardized parts and assem- blies that are installed in several STIHL power tool models. Reference is made to these handbooks in the appropriate chapters of this manual. Remove the chain sprocket cover and secure the machine to the assembly stand with the sprocket cover nuts. Machines with a quick chain tensioning system and secure with one M8 nut and washer. The special servicing tools mentioned in the descriptions are listed in the last chapter of this ma- nual. Use the part numbers to identify the tools in the "STIHL Special Tools" manual. The manual lists all special servicing tools currently available from STIHL. The complete unit can then be swivelled to the best position for the ongoing repair. This leaves both hands free. Symbols are included in the text and pictures for greater clarity. The meanings are as follows: Always use original STIHL replacement parts. They can be identified by the STIHL part number, the and the STIHL parts symbol ( The symbol may appear alone on small parts. As the design concept of model 024 and 026 chainsaws is almost identical, the descriptions and servicing procedures generally apply to both. Differences are described in detail. In the descriptions: • = Action to be taken as shown in the illustration (above the text) logo Servicing procedures on the carburetor are described in the "Carburetors" handbook. - = Action to be taken that is not shown in the illustration (above the text) You should make use of the illustrated parts lists while carrying out repair work. They show the installed positions of the individual components and assemblies. In the illustrations: = Pointer = Direction of movement Refer to the latest edition of the relevant parts list to check the part numbers of any replacement parts needed. Parts lists on microfiche and CD- ROM are always more up to date than printed lists. Service manuals and all technical information bulletins describing engineering changes are intended exclusively for the use of STIHL servicing dealers. They must not be passed to third parties. A fault on the machine may have several causes. To help locate the fault, consult the troubleshooting charts for all assemblies in the "Standard Repairs, Troubleshoot- ing" handbook. Refer to the "Technical Informa- tion" bulletins for engineering changes which have been intro- duced since publication of this service manual. Technical informa- tion bulletins also supplement the parts list until a revised edition is issued. 1 VA 133RA001 Servicing and repairs are made considerably easier if the machine is mounted on assembly stand (1) 5910 890 3100. 2 024, 026

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  5. 3. SPECIFICATIONS 3.1 Engine STIHL single-cylinder two-stroke engine with special impregnated cylinder bore 024 024 S 026 42 cm3(2.56 cu.in) 42 mm (1.65 in) 30 mm (1.18 in) 2.1 kW (2.85 bhp) at 7,000 rpm 44.3 cm3(2.70 cu.in) 42 mm (1.65 in) 32 mm (1.26 in) 2.3 kW (3.1 bhp) at 7,000 rpm 48.7 cm3(2.97 cu.in) 44 mm (1.73 in) 32 mm (1.26 in) 2.6 kW (3.5 bhp) at 7,000 rpm Displacement: Bore: Stroke: Engine power to ISO 7293: Max. permissible engine speed with bar and chain: Idle speed: Bearings: 13,000 rpm 2,500 rpm Crankshaft supported in heavy-duty deep-groove ball bearings, needle cages on small and big ends 10 mm (0.39 in) Single pawl system min. 1/2 turn 3.5 mm (0.14 in) dia. Centrifugal clutch without linings 3,600 rpm 13,000 rpm 14,000 rpm Piston pin diameter: Rewind starter: Reserve pull on rope rotor: Starter rope: Clutch: Clutch engages at: Crankcase leakage test at gauge pressure: under vacuum: 0.5 bar (7.25 psi) 0.5 bar (7.25 psi) 3.2 Fuel System Carburetor: Setting High speed screw H: Low speed screw L: Diaphragm carburetor approx. 1 turn open approx. 1 turn open (standard setting) Carburetor leakage test at gauge pressure: Function of tank vent at gauge pressure: under vacuum: * Fuel tank capacity: Octane number: Fuel mixture: 0.8 bar (11.6 psi) ≤ 0.3 bar (4.35 psi) ≤ 0.05 bar (0.725 psi) 0.47 L (16 fl.oz) min. 90 RON Regular brand-name gasoline and two-stroke engine oil 50:1 with STIHL 50:1 two-stroke engine oil 25:1 with other brand-name two-stroke, air-cooled engine oils Large area, bisectional flat filter, additional prefilter in carburetor box cover Mix ratio: Air filter: * Original tank vent 024, 026 3

  6. 3.3 Ignition System Type: Electronic magneto ignition (breakerless) with integral trigger unit 0.2-0.3 mm (0.008-0.012 in) Bosch WSR 6F, NGK BPMR 7 A or Champion RCJ 6Y 0.5 mm (0.020 in) Air gap: Spark plug (suppressed): Electrode gap: 3.4 Cutting Attachment Guide bars: STIHL Rollomatic with nose sprocket, corrosion-resistant finish and induction hardened rails 32, 37 and 40 cm (13, 15, 18 in) 0.325" (8.25 mm) Rapid chain 7-tooth 0.325" 18.3 m/s (60 ft/s) at 9,500 rpm Speed-controlled or adjustable reciprocating pump Bar lengths: Oilomatic chain: Chain sprocket: Chain speed: Chain lubrication: Oil feed rate on non-adjustable pump: 6 cm3/min (0.2 fl.oz/min) at 6,000 rpm 9.5 cm3/min (0.3 fl.oz/min) at 10,000 rpm 4.5-11.5 cm3/min (0.15-0.4 fl.oz/min) at 10,000 rpm 0.32 L (11 fl.oz) on adjustable pump: Oil tank capacity: 3.5 Special Accessories 3.5.1 For User ElastoStart Air filter, "fleece" 024 0.325", 8-tooth chain sprocket 0000 190 3401 1121 120 1625 1121 640 2001 1121 640 2005 1121 007 1030 1121 007 1027 (up to serial number X 30 976 774) 1121 007 1044 (from serial number X 30 976 775) 1121 007 1001 1121 007 1037 1121 007 1002 1121 007 1038 1121 007 1004 1121 007 1039 1121 007 1005 1121 007 1040 1121 007 1035 1121 007 1041 1) 2) Intake air preheating kit 024 Intake air preheating kit 026 Intake air preheating kit 026 0.325", 7-tooth rim sprocket kit 1) 2) 1) 2) 1) 2) 1) 2) 1) 2) 0.325", 8-tooth rim sprocket kit 3/8" Picco, 7-tooth rim sprocket kit 3/8" Picco, 8-tooth rim sprocket kit 3/8", 7-tooth rim sprocket kit Chain scabbard extension (from 45 cm/18 in) CAT mounting kit 0000 792 9131 1121 007 1042 1) 024 2) 026 4 024, 026

  7. 3.5.2 For Service Carburetor parts kit 024, small Carburetor parts kit 024, large Carburetor parts kit 024/026, large Carburetor parts kit 024/026, large Gasket set 024/026 1118 007 1060 (Tillotson) 1118 007 1065 (Tillotson) 1121 007 1062 (Walbro) 1118 007 1066 (Walbro WT 22) 1121 007 1050 3.6 Tightening Torques Plastoform screws are used for polymer components. These screws form a permanent thread when they are installed for the first time. They can be removed and installed as often as necessary without detrimentally affecting the strength of the screwed assembly, providing the specified tightening torque is observed. For this reason it is essential to use a torque wrench. Fastener Thread For component size Torque Nm Remarks lbf.ft Pan head screw Countersunk screw M4x8 PT4x12 Cover plate/chain tensioner Cover plate/chain sprocket cover Bar mounting Bar mounting Cover to crankcase, sprocket side Decompression valve Spark arresting screen Generator Front handle top/bottom (W version) Front handle, top (polymer) Front handle, bottom (polymer) Handle molding Hand guard, left Shroud to cylinder Chain catcher/plug Spiked bumper (with self-locking nut) Crankcase Air filter Fan housing Clutch carrier Annular buffer to tank housing, left Annular buffer to tank housing, right 3.0 2.2 2.5 23.0 30.0 1.8 17.0 22.0 1) 2) 1) Collar screw Collar screw Spline screw M8x21.5 M10/M8 IS-M4x12 3) 3.0 14.0 2.0 2.0 2.2 10.3 1.5 1.5 M10x1 B4.2x9.5 M3.5x12 IS-P6x19 4) Self-tapping screw Spline screw Self-tapping screw 2) 7.0 5.0 5.0 1.6 4.0 3.5 2.8 5.2 3.7 3.7 1.2 3.0 2.6 2.1 Self-tapping screw Self-tapping screw Self-tapping screw Screw assembly Slotted nut Self-tapping screw Spline screw IS-P6x32.5 IS-P6x21.5 B3.9x19 IS-M4x16 M5 IS-P6x19 IS-M5x12 7.5 9.0 2.0 4.0 50.0 5.5 6.6 1.5 3.0 37.0 Spline screw Mutter Spline screw IS-M5x20 M5 IS-M4x16 M12x1L IS-P6x26.5 Self-tapping screw 5.0 3.7 Self-tapping screw IS-P6x19 5.0 3.7 024, 026 5

  8. Fastener Thread For component size Torque Nm Remarks lbf.ft Spline screw Spline screw IS-M5x12 IS-M5x16 Annular buffer plate Muffler to crankcase (Cat version) Muffler to crankcase (non-Cat version) Muffler to cylinder Upper casing to muffler (non-Cat version) Upper casing to muffler (Cat version) Flywheel Side plate Side plate Stud to cylinder, left Stud to cylinder, right Carburetor Cylinder Spark plug Ignition module Oil pump 8.0 5.9 2) 10.0 7.5 2) Spline screw IS-M5x12 10.0 10.0 7.5 7.5 2) 2) Spline screw Spline screw IS-M5x12 IS-M5x12 10.0 7.5 Spline screw IS-M5x16 10.0 33.0 3.0 3.0 1.4 1.4 3.5 10.5 25.0 7.0 3.5 7.5 24.4 2.2 2.2 1.1 1.1 2.6 7.7 18.5 5.2 2.6 Nut Spline screw Self-tapping screw Stud Stud Nut Spline screw M8x1 M4x8 BM4x16 M5x8.5 M5x8.5 M5 IS-M5x20 M14x1.25 IS-M5x20 IS-M4x12 1) 3) Spline screw Spline screw 2) 5) Use the following procedure when refitting a P screw in an existing thread: – Place the P screw in the hole and rotate it counterclockwise until it drops down slightly. – Tighten the screw clockwise to the specified torque. This procedure ensures that the screw engages properly in the existing thread and does not form a new thread, i.e. the thread is not weakened. 1) On machines with quick chain tensioner 2) Secure screw with Loctite 242. 3) Secure screw with Loctite 270. 4) On 026 only 5) A washer must be fitted under the screw head. Note: Screws secured with adhesive (Loctite) are easier to release if they are heated with a hot air blower (hair dryer). Take care on polymer components. Power screwdriver setting for use in polymer: max. 600 rpm for Plastoform screws 6 024, 026

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  10. 4. 4.1 CLUTCH, CHAIN DRIVE, CHAIN BRAKE AND CHAIN TENSIONER Clutch Drum and Chain Sprocket VA 170RA005 VA 143RA007 • Remove the needle cage. • If the clutch drum is still service- able, use No. 120 emery paper or emery cloth (grain size approx. 120µm) to clean and roughen its friction surface. - Remove the chain sprocket cover. - Clean and inspect the clutch drum/chain sprocket. • Disengage the chain brake by pulling the hand guard toward the front handle. Reassemble in the reverse sequence. - Clean stub of crankshaft. Wash needle cage in clean white spirit and lubricate with grease - see 13.2. 1 2 - Replace damaged needle cage. - On 026, rotate clutch drum/chain sprocket and apply slight pressure at the same time until driver on oil pump worm engages the notch on the drum’s circumference. 100% VA 133RA002 VA 145RA006 ! 80% • Remove the E-clip (1). Important: If there are noticeable wear marks on the inside diameter of the clutch drum, check its wall thickness. If it is less than 80% of the original wall thickness, fit a new clutch drum. • Remove the washer (2). - If machine is equipped with a rim sprocket, refit it so that the cavities face outwards. Note: If the clutch drum has to be replaced, also check the brake band - see 4.3.2. VA 133RA003 - If a rim sprocket is fitted, pull it off. • Pull off the clutch drum/chain sprocket. 024, 026 7

  11. 4.2 Clutch Troubleshooting chart - see "Standard Repairs, Trouble- shooting" handbook. - Remove the clutch drum/chain sprocket - see 4.1. - Remove the air filter - see 12.1. VA 133RA007 VA 133RA010 • Unscrew the clutch in the direction of the arrow (left-hand thread). - Install spark plug and torque down to 25 Nm (18.5 lbf.ft). • On machines with a decompres- sion valve, make sure the cover is properly seated. - Disassemble and reassemble the clutch - see "Standard Repairs, Troubleshooting" handbook. VA 133RA004 VA 133RA008 VA 133RA035 • Unscrew slotted nut from the shroud. • On 024, if a cover washer is fitted behind the original clutch, do not refit it when installing the new clutch. • If the shroud is replaced on a 026 machine without decompres- sion valve, seal the opening in the shroud with the cap. - Remove the shroud. - Pull off the spark plug boot. 1 VA 133RA006 VA 133RA009 VA 133RA005 2 • Screw clutch onto crankshaft and torque down to 50 Nm (37 lbf.ft). • Check condition of heat shield (foil) and fit a new one if necessary. - Unscrew the spark plug. • Close the decompression valve (1), where fitted. - Remove locking strip from cylinder. - Fit the shroud. • Push the locking strip (2) 0000 893 5903 into the cylinder. 8 024, 026

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