CONTENTS

1. Safety Precautions 1 7. Rewind Starter 28 1. SAFETY

PRECAUTIONS
7.1 Routine Maintenance 28
2. Introduction 2
7.2 Rewind Spring 28
If the chainsaw is started up in the
7.2.1 Replacing 28
3. Specifications 3 course of repairs or maintenance
7.2.2 Tensioning 29
work, observe all local and country-
3.1 Engine 3
specific safety regulations as well
3.2 Fuel System 3 8. AV Handle System/
as the safety precautions and
3.3 Ignition System 4 Handle Housing 30
warnings in the owner's manual.
3.4 Cutting Attachment 4
8.1 Annular Buffers 30
3.5 Special Accessories 4
8.2 Front Handle 31 Gasoline is an extremely flamm-
3.5.1 For User 4
8.3 Handle Housing 31 able fuel and can be explosive in
3.5.2 For Service 4
8.4 Switch Shaft 33 certain conditions.
3.6 Tightening Torques 5
8.5 Contact Spring 34
8.6 Throttle Trigger/ Improper handling may result in
4. Clutch, Chain Drive,
Interlock Lever 34 burns or other serious injuries.
Chain Brake and
Chain Tensioner 6
9. Chain Lubrication 36 Warning! Do not smoke or bring

- 4.1

4.2
4.3
4.4
4.4.1
4.4.2
Clutch Drum/
Chain Sprocket
Chain Catcher
Clutch
Chain Brake
Checking Function
Disassembly
6
7
7
8
8
8
9.1
9.2

9.3
9.4
9.5
Saugkopf
Connector/
Suction Hose
Vent Valve
Worm
Oil Pump
36

36
37
38
38
any fire or flame near the fuel. All
work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.

Wash hands thoroughly after

every contact with waste oil.
4.4.3 Assembly 10
10. Fuel System 39
4.5 Front Chain Tensioner 12 Do not pour waste oil down the
4.6 Side Chain Tensioner 12 10.1 Air Filter 39 drain or allow it to soak into the
10.2 Carburetor 41 , ground.
5. Engine 13 10.2.1 Leakage Test 41
10.2.2 Removing and Collect waste oil and take it to an
5.1 Exhaust Muffler/Spark
Installing 42 official disposal site for environ-
Arresting Screen 13
10.2.3 Adjustment (except ment-friendly disposal.
5.2 Leaking Test 14
023 Land USA) 43
5.2.1 Preparations 14
10.2.4 Adjustment
5.2.2 Pressure Test 15
(023 L and USA) 44
5.2.3 Vacuum Test 15
10.3 Tank Vent 45
5.3 Oil Seals 16
10.4 Pickup Body 46
5.4 Removing and
10.5 Suction Hose 46
Installing 18
10.6 Manual Fuel Pump 47
5.5 Cylinder 18
10.6.1 Fuel Hoses 47
5.6 Piston 20
10.7 Fuel Tank 48
5.7 Piston Rings 22
5.8 Crankshaft 22
5.9 Connecting Rod
11. Special Servicing
Tools and Aids 50
(021 up to Serial No.
X 34 944 402) 23 11.1 Special Servicing Tools 50
5.10 Decompression Valve 24 11.2 Servicing Aids 52

6. Ignition System 24
6.1 Spark Plug Boot 24
6.2 Ignition Lead 25
6.3 Ignition Module 25
6.3.1 Ignition Timing 26
6.3.2 Removing and
Installing 26
6.4 Flywheel 27

STIHL®
If © 2001 Andreas Stihl AG & Co., Waiblingen

021,023,025 1
2. INTRODUCTION

This service manual contains The special servicing tools mentio- outer 10 mm bore (3) in the
detailed descriptions of all the ned in the descriptions are assembly stand.
repair and servicing procedures listed in the last chapter of this
specific to this power tool series. manual.
There are separate handbooks for Use the part numbers to identify
servicing procedures for the tools in the "STIHL Special
standardized parts and Tools" manual.
assemblies that are installed in The manual lists all special
several STIHL power tool models. servicing tools currently available
Reference is made to these from STIHL.
handbooks in the appropriate
chapters in this manual. Symbols are included in the text
and pictures for greater clarity. 1
As the design concept of model The meanings are as follows:
021, 023 and 025 chainsaws is
almost identical, the descriptions In the descriptions:
and servicing procedures in this
manual generally apply to all • = Action to be taken as
three models. Differences are shown in the illustration
described in detail. (above the text)

You should make use of the = Action to be taken that

illustrated parts lists while carrying is not shown in the
out repair work. They show the illustration To service the underside of the
installed positions of the individual (above the text) machine (e.g. remove the oil
components and assemblies. pump), turn the machine through
In the illustrations: 180 degrees and mount it so that
Refer to the latest edition of the one clamp screw engages the
relevant parts list to check the part + = Pointer inne, 1O mm bore (1) in the
numbers of any replacement parts assembly stand.
needed. _. = Direction of movement
Parts lists on microfiche and Note: Pull the hand guard back
CD-ROM are always more up to Service manuals and all technical against the front handle for this
date than printed lists. information bulletins describing purpose.
engineering changes are intended
A fault ori the machine may have exclusively for the use of STIHL The powerhead can then be
several causes. To help locate the servicing dealers. They must not swivelled to the best position for
fault, consult the troubleshooting be passed to third parties. the ongoing repair and this leaves
charts for all assemblies in the both hands free.
"Standard Repairs, Troubleshoo-
ting" handbook. Always use original STIHL
replacement parts.
Refer to the "Technical Informa- They can be identified by the
tion" bulletins for engineering STIHL part number,
changes which have been intro- the ST/HL® logo
duced since publication of this and the
service manual. Technical informa- STIHL parts symbol Is/®
tion bulletins also supplement the The symbol may appear alone on
parts list until a revised edition is small parts.
issued. t:"-:i~'."------2
;;
"'
0
<(

1 3 ~

Servicing and repairs are made

considerably easier if the clamp
(1) 5910 890 2000 is used to
mount the machine on assembly
stand (2) 5910 890 3100 so that
one clamp screw engages the
t
2 021,023,025
3. SPECIFICATIONS

3.1 Engine

STIHL single cylinder two-stroke engine with special impregnated cylinder bore

021 023 L 023 025

Displacement: 35.2 cm 3 40.2 cm 3 40.2 cm 3 44.3 cm 3

2.15 cu.in 2.45 cu.in 2.45 cu.in 2.70 cu.in
Bore: 40 mm 40mm 40mm 42mm 42mm
1.57 in 1.57 in 1.57 in 1.65 in
Stroke: 28 mm 32mm 32mm 32mm 32mm
1.10 in 1.26 in 1.26 in 1.26 in
Power output to ISO 7293: 1.5 kW (2.0 bhp) 1.1 kW ( 1.5 bhp) 1.9 kW (2.6 bhp) 2.2 kW (3.0 bhp)
at 9,000 rpm at 6,500 rpm at 9,500 rpm at 10,000 rpm
Max. permissible engine speed
1)
(with bar and chain): 11,500 rpm 12,500 rpm 13,000 rpm
Idle speed: 2,800 rpm
Bearings: Crankshaft supported in heavy-duty ball bearings, needle cages on
small and big ends
Cylindrical rollers on big end 2)
Piston pin diameter: 10 mm (0.39 in)
Rewind starter: Pawl engagement
Pawls: Single pawl system
Reserve pull on rope rotor: min. 1/2 turn
Starter rope: 3.0 mm (0.12 in) dia.
Clutch: Centrifugal clutch without linings
Clutch engages at: 3,600 rpm 4,100 rpm 3,500 rpm 3,500 rpm
Crankcase leakage
test
at gauge pressure: 0.5 bar (7.25 psi)
under vacuum: 0.5 bar (7.25 psi)

3.2 Fuel System

Carburetor: Diaphragm carburetor

Standard setting on carburetors
with three adjusting screws
High speed screw H: Open approx. 1 turn
Low speed screw L: Open approx. 1 turn
Carburetor leakage test
at gauge pressure: 0.8 bar (11.6 psi)
Function of tank vent
at gauge pressure: s 0.3 bar (4.35 psi)
under vacuum: s 0.05 bar (0.725 psi)
Fuel tank capacity: 0.47 I (1 US pt)
Octane rating: min. 90 RON (US/CAN; pump octane min. 87)
Fuel mixture: Regular brand name gasoline
and two-stroke engine oil
Mix ratio: 50:1 with STIHL two-stroke engine oil
25:1 with other brand name two-stroke, air-cooled engine oils
Air filter:Box tilter, fabric or fleece filter

1) Not adjustable
2) 021 only up to serial number X 34 944 402

021,023,025 3
3.3 Ignition System Type: Electronic magneto
ignition (breakerless)
with integral trigger unit
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in)
Spark plug (suppressed): Bosch WSR 6F,
NGK BPMR 7 A,
Champion RCJ 6Y or
Autolite 2984
Electrode gap: 0.5 mm (0.020 in)

3.4 Cutting Attachment Chain lubrication: Fully automatic speed-controlled

oil pump with rotary piston

Oil deivery rate: approx. 7.5 cm 3/min (0.25 fl.oz/min)

at 10,000 rpm

Oil tank capacity: 0.20 I (0.4 US pt)

3.5 Special Accessories

3.5.1 For User STIHL repair kit 1123 900 5000

3/8" P, 8-tooth rim sprocket kit 1123 007 1001
.325", ?-tooth rim sprocket kit 1123 007 1003
.325", 8-tooth rim sprocket kit 1123 007 1002
1/4", 8-tooth spur sprocket 1123 640 2010
3/8" P, ?-tooth spur sprocket 1123 640 2000
.325", ?-tooth spur sprocket 1123 640 2015
.325", 8-tooth spur sprocket 1123 640 2020
Side chain tensioner kit 1123 007 1000

3.5.2 For Service Carburetor parts kit 1123 007 1061

l
4 021,023,025
 3.6 Tightening Torques

DG screws are used in the polymer and light-alloy 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 Torque Remarks

size Nm lbf.ft

Spline screw IS-DG4x15 Chain brake cover 2.0 1.5

Spline screw IS-DG4x15 Handle molding 1.6 1.2
Spline screw IS-DG4x15 Connector 2.5 1.8
(engine/oil pump)
Spline screw IS-DG4x15 Ground wire 3.5 2.6
(to cylinder)
Spline screw IS-DG5x24 Handle housing/ 3.5 2.6

- Spline
Spline
Spline
Spline
Spline
screw
screw
screw
screw
screw
IS-DG5x24
IS-DG5x24
IS-DG5x24
IS-DG5x24
IS-DG5x24
front handle
Hand guard
Hand guard
Fan housing
Buffer (to front handle)
Buffer (to engine)
3.5
3.7
3.5
3.5
3.5
2.6
2.8
2.6
2.6
2.6
1)

Spline screw IS-DG5x24 Ignition module 4.0 3.0

(to engine housing)
Spline screw IS-DG5.3x40 Cylinder 9.5 7.0
(to engine housing)
Collar screw DG8x18 Guide bar mounting 16.0 11.8
Collar screw (rear) DG8x18 Guide bar mounting 8.0 5.9 3)
M12x1 L Carrier (clutch) 50.0 37.0
M14x1.25 Spark plug 25.0 18.5
Hexagon nut M5 Muffler 7.0 5.2
Hexagon nut M5 Filter housing/carburetor 2.7 2.0
Collar nut M8x1 Flywheel to crankshaft 28.0 21.0
M12x1 .5 Decompression valve 14.0 10.3 2)
Slotted nut M5 Filter base/carburetor 2.0 1.5 1)
Spline screw IS-DG5x16 Spiked bumper 3.7 2.8

Use the following procedure to fit a DG screw in an existing thread:

- Place the DG screw in the hole and rotate it counterclockwise until 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,
which would weaken the assembly.

1) 023 L
2) On easy start version only
3) With quick chain adjuster

Note: Power screwdriver speed settings for polymer: Plastoform screws max. 600 rpm
DG screws max. 500 rpm

021,023,025 5
4. CLUTCH, CHAIN DRIVE, CHAIN BRAKE, CHAIN TENSIONER
4.1 Clutch Drum/Chain Sprocket

- Remove the chain sprocket • Take the needle cage out of the • If the clutch drum/chain sprocket
cover. sprocket. is still serviceable, use No. 120
emery paper or emery cloth
• Disengage the chain brake by - Clean and inspect the clutch (grain size approx. 120µm) to
pulling the hand guard toward drum/chain sprocket. clean and roughen its friction
the front handle. surface.

Reassemble in the reverse

sequence.

l~t~
- Clean stub of crankshaft.
Wash needle cage in clean white
spirit and lubricate with grease -
see 11.2.
1----s--------+-
~ 0 - Replace damaged needle cage.

!/;, ! ~~~=~ 100% - Rotate clutch drum/chain

~~ sprocket and apply slight
pressure at the same same until
oil pump drive spring engages
• Remove the E-clip (1 ). Important: If there are noticeable properly.
wear marks on the inside diameter
• Remove the washer (2). of the clutch drum, check its wall - If rim sprocket was fitted, re-
thickness. If it is less than 80% of install it with the cavities facing
the original wall thickness, fit a outward.
new clutch drum.

Note: If the clutch drum has to be

replaced, also check the brake
band - see 4.4.2.

- Remove the rim sprocket, if fitted.

• Pull off the clutch drum/chain

sprocket.

6 021,023,025
4.2 Chain Catcher 4.3 Clutch

Troubleshooting chart - see

"Standard Repairs, Trouble-
shooting" handbook.

- Remove the clutch drum/chain

sprocket - see 4.1 .

- Remove the air filter - see 10.1.

- On 023 L, remove the filter base -

see 10.2.2.

Sprocket cover with integrally • Unscrew clutch from the

molded chain catcher (1 ). crankshaft clockwise (left-hand
thread).
If the chain catcher has broken
off (2), repair as follows: - Service the clutch - see
"Standard Repairs,
Trouble-shooting" handbook.

• Pry the plug out of the front right- •Takeout the shutter.
hand AV element.
- Pull boot off the spark plug and
then unscrew the spark plug.

A
/21 '

~ 1A11/i "'
;-(!JJ
• Oil the cylindrical part (1) of the - Close the decompression valve, • Screw on the clutch and tighten
replacement chain catcher. if fitted. down to 50 Nm (37 !bf.ft).

• Push the chain catcher into the • Push the locking strip (1) - Install the clutch drum/chain
AV element (2) and engage the 0000 893 5903 into the cylinder. sprocket - see 4.1.
peg (3) in the housing bore (4) at
the same time.
021,023,025 7
 4.4 Chain Brake
4.4.1 Checking Function 4.4.2 Disassembly

The chain brake is one of the most - Remove the clutch drum/chain
important safety devices on the sprocket - see 4.1.
chainsaw. Its efficiency is
measured in terms of the chain - Release brake spring tension by
braking time, i.e. the time that pushing hand guard forward.
elapses between activating the
brake and the saw chain coming - Remove upper bumper strip from
to a complete standstill. The tensioner.
shorter the braking time, the better
the efficiency and protection
offered against being injured l:;>y
the rotating chain.
- Remove locking strip from
cylinder. Contamination (with chain oil,
chips, fine particles of abrasion,
- Insert spark plug and tighten etc.) and smoothing of the friction
down to 25 Nm (18.5 lbf.ft). surfaces of the brake band and
clutch drum impair the coefficient
• If spark plug has a separate of friction. This, in turn, reduces
terminal nut, make sure it is the frictional forces and thus
properly tightened down. prolongs the braking time. A
fatigued or stretched brake spring
- Fit boot on the spark plug. has the same negative effect. )
- Start the engine.

- With the chain brake activated

(locked), open throttle wide for
a brief period (max. 3 seconds) -
the chain must not rotate.
)
- With the chain brake released,
open throttle wide and activate
the brake manually - the chain •Takeout the screws.
must come to an abrupt
stop. - Remove the cover.

Note: The braking time is in

order if deceleration of the
saw chain is imperceptible to
the eye.

• Fit the shutter so that its lugs • Carefully ease the brake spring
engagetherecessesinthe off the anchor pin and take it off
handle housing. the bell crank.

- Install the air filter - see 10.1.

8 021,023,025
• Pry the brake band out of the •Takeout the screw. • Remove the washer.
engine housing.

- Disconnect brake band from bell

crank.

Replace the brake band if: • Remove the E-clip. • Carefully pry the hand guard (1)
and bell crank (2) off their pivot
- there are noticeable signs of pins and lift away together.
wear (large arel:IS on inside
diameter and/or parts of outside - Pull the bell crank out of the
diameter) and hand guard.

- its remaining thickness is

< 0.6 mm (0.024").

Important! Thickness of brake

band must not be less at any point.

• If the brake band is still

serviceable, use No. 120 emery
paper or emery cloth (grain size
approx. 120µm) to clean and
roughen its entire friction surface
(inside diameter).

• Remove strap from bell crank • Up to serial number

pivot pin (1 ). X 28 310 254, remove the
spring (1 ).
• Push the strap sideways and lift
it off the hand guard pivot pin (2). • Pull out the cam lever (2).

021,023,025 9
 4.4.3 Assembly

- Lubricate sliding and bearing

points of chain brake with STIHL
multipurpose grease or,
preferably, Molykote grease -
see 11.2.

- From serial number

X 28 310 255, install the flat
spring.

• From serial number • Position the hand guard ( 1)

X 28 310 255, remove the flat against the pivot pin and fit the
spring. other side of the hand guard
over the housing.
- Inspect parts and replace if
damaged. • Position the bell crank (2)
against the pivot pin.
- Clean the entire housing recess
for the chain brake. • Press the cam lever (3) slightly
L------' ~ downward and push the hand
- If the groove of the brake spring guard and bell crank onto their
anchor pin is worn, replace the ~-=-<!~~~-1 pivot pins.
housing.

~ ~
- Up to serial number
X 28 310 254, fit the cam lever.

• Attach spring to cam lever (open

side of spring hook facing
outwards) and slip it over the
pivot pin

J
~
-----
:====>

~;) 1~i
• Insert the bell crank in the side of • Check that cam lever or flat
the hand guard so that the short spring (1) is properly located on
arm of the bell crank points to face (2) of hand guard bearing
top of hand guard. boss.

10 021,023,025
• Fit the washer on the pivot pin. • Hook the brake spring onto the • Use the assembly (2)
bell crank. 1117 890 0900 to attach the
brake spring (1) to the anchor
pin.

• Fit strap on the pivot pin (1) • Position the brake band around - Fit the bushing in the hand guard.
and locate it in the pivot pin's the clutch and push it into the
groove. engine housing. - Insert M5x24 screw and tighten
down to 3.5 Nm (2.6 lbf.ft).
• Slip the other end of the strap
over the bell crank pivot pin (2). • On 023 L, push the rubber
bushing (1) into the hand guard
- Secure strap with E-clip. (2).

- Coat brake band with chain oil - Insert M5x32 screw (3) and
(STIHL Bioplus), see 11.2, to tighten down to 3. 7 Nm
protect it from corrosion and help (2.8 lbf.ft).
reduce "snatching" during the
first few brake applications. - Fit the cover.

- Tightelil screws to 2.0 Nm

(1.5 lbf.ft).

- Install clutch drum/chain

sprocket - see 4.1.

• Attach the brake spring to the - Check operation of chain brake -

bell crank. see 4.4.1.

021,023,025 11
4.5 Front Chain Tensioner 4.6 Side Chain Tensioner

\\V
/ '::::,_Jf---~:';;:;:;;;;:::
/

- Remove the chain sprocket - Remove the chain sprocket • Pull the spur gear out of the
cover. cover. cover.

• Pull the cover out of the engine •Takeout the screw.

housing.
- Pull the complete tensioner
assembly out of the engine
housing.

1 4 2 3

• Unscrew the nut (1) from the • Take the thrust pad (1) off the • Pull the tensioner slide off the
adjusting screw (2). adjusting screw (2). cover.

• Take the adjusting screw out of • Rotate the spur gear (3) until the - Take the adjusting screw out of
the cover (3). adjusting screw comes out of the the cover.
tensioner slide (4).
Reverse the above sequence to - Inspect the teeth on the spur
install the chain tensioner. gear and adjusting screw.
Replace both parts if necessary.

Reverse the above sequence to

install the chain tensioner.

- Coat teeth of adjusting screw

and spur gear with grease, see
11.2, before refitting.

12 021,023,025
5. ENGINE
5.1 Exhaust Muffler/Spark Arresting Screen

This machine does not have a

conventional crankcase. The
engine consists of the cylinder,
piston, crankshaft and engine pan.

Troublehooting - see "Standard

Repairs, Troublehooting"
handbook.

• Remove spark arresting screen, • On 023 and 025, remove gasket

if fitted. (1) und heat shield (2).

- Clean the spark arresting screen

or fit a new one if necessary.

\
_I
I'
L
' -

"~
a:
~

• Unscrew the nuts. • Remove the upper casing from • Remove the screws from the
the lower casing (not on 023 L). flange.
- Remove the muffler.
Reassemble in the reverse
sequence.

- Use a new gasket.

- Fit new locknuts and torque

down to 7.0 Nm (5.2 lbf.ft).
~~,

Oo
00
o 0 o
0 0

• Pull away the cover plate. • If necessary, take the baffle out
of the lower casing.

021,023,025 13
5.2 Leakage Test 5.2.1 Preparations

Defective oil seals and gaskets or

cracks in castings are the usual
causes of leaks. Such faults allow
supplementary air to enter the
engine and upset the fuel-air
mixture.

This makes adjustment of the

prescribed-idle speed difficult, if
not impossible.

Moreover, the transition from idle

speed to part or full throttle is not - Remove the muffler - see 5.1. • Fit the test flange (1)
smooth. 1118 850 4200 in place of the
• Fit the sealing plate (1) carburetor.
The engine housing can be 0000 855 8106 between the
checked thoroughly for leaks with muffler and cylinder.
the carburetor and crankcase
tester and the vacuum pump. Note: The sealing plate must
completely fill the space between
the two mounting screws.

• Slip the flange (2) 1123 855

4200 over the screws.

• Fit the sleeves (3) 1123 851

8300 on the screws.

• Fit the nuts (4) and tighten down

securely.

- Remove the carburetor - see

10.2.2.
• Pull out decompression valve
- Set the piston to top dead center button, if fitted.
(T.D.C.). This can be checked
through the inlet port. - Check that spark plug is properly
tightened down.

- Check tester 1106 850 2905 and

vacuum pump 0000 850 3501 for
leaks.

• Inspect carburetor gasket and fit

new one if necessary.

14 021,023,025
5.2.2 Pressure Test 5.2.3 Vacuum Test

Oil seals tend to fail when sub-

l~) jected to a vacuum, i.e. the sealing
lip lifts away from the crankshaft
1//)~
during the piston's induction stroke
because there is no internal
counterpressure.

- An additional test can be carried

out with the vacuum pump to

\ ~
detect this kind of fault.

- Carry out preparations -

- Carry out preparations - • However, if the indicated see 5.2.1.
see 5.2.1. pressure drops, the leak must
be located and the faulty part
• Connect pressure hose of tester replaced.
1106 850 2905 to nipple on test
flange. Note: To find the leak, coat the
suspect area with oil and
pressurize the crankcase again.
Bubbles will appear if a leak exists.

- If the decompression valve is

leaking, fit a new one - see 5.10.

- Repeat the pressure test.

- Carry out the vacuum test - see

5.2.3.

- After finishing the test, open the

vent screw and disconnect the
hose.
• Close the vent screw (1) on the • Connect suction hose of vacuum
rubber bulb. - Remove the test flange. pump 0000 850 3501 to test
flange nipple.
- Pump air into the engine housing - Install the carburetor - see 10.2.2.
with the rubber bulb until the
gauge indicates a pressure of - Remove the flange.
0.5 bar (7.25 psi). If this pressure
remains constant for at least 20 - Remove the sealing plate.
seconds, the housing or
decompression valve, if fitted, is - Install the muffler - see 5.1.
airtight.

• Close the vent screw (1) on the

pump.

• Operate lever (2) until pressure

gauge (3) indicates a vacuum of
0.5 bar (7.25 psi).

021,023,025 15
 5.3 Oil Seals

Note: If the vacuum reading It is not necessary to disassemble - Clamp the puller arms.
remains constant, or rises to no the complete engine housing if
more than 0.3 bar (4.25 psi) within only the oil seals have to be - Pull out the oil seal.
20 seconds, it can be assumed replaced.
that the oil seals are in good Important: Take special care not
condition. to damage crankshaft stub.
However, if the pressure continues
to rise (reduced vacuum in the
engine housing), the oil seals must
be replaced.

- After finishing the test, open the

vent screw and disconnect the
hose.

- Remove the test flange. Clutch side:

- Install the carburetor - see 10.2.2. - Remove the clutch - see 4.3.

- Remove the test flange. - Remove the oil pump - see 9.5.

- Remove the sealing plate.

- Install the muffler -

see 5.1.

• Ease the retaining ring out of the • If an oil seal with clamping ring
crankshaft. (1) is installed, use puller and
No. 3.1 jaws to remove the
clamping ring. Pry the sealing
ring (2) out of the housing.

- Clean sealing face on crankshaft

stub with standard commercial,
solvent-based degreasant
containing no chlorinated or
halogenated hydrocarbons -
see 11.2.

Note: If the cylinder and engine

pan are assembled, only oil seals
9638 003 1581 (with clamping
ring) may be installed.

- Lubricate sealing lips of oil seal

with grease - see 11.2.

• Apply puller (1) 5910 890 4400 - Thinly coat the outside diameter
Uaws 0000 893 3711 with No. 6 of the oil seal with sealant - see
profile). 11.2.

16 021,023,025
 - Clamp the puller arms. • Screw the guide sleeve (2)
1123 894 7700 onto the
- Pull out the oil seal. crankshaft.

Important: Take special care not

to damage crankshaft stub.

Note: Remove the oil seal with

clamping ring as described for
clutch side.

- Clean sealing face on crankshaft

- Position the oil seal so that the stub with standard commercial,
clamping ring faces upwards. solvent-based degreasant
containing no chlorinated or
• Use the press sleeve (1) halogenated hydrocarbons - see
1123 893 2400 to install the oil 11.2.
seal.
Note: If the cylinder and engine
- Wait about one minute, then pan are assembled, only oil seals
rotate the crankshaft. 9638 003 1581 (with clamping
ring) may be installed.
- Fit a new retaining ring.
- Lubricate sealing lips of oil seal
- Install the oil pump - see 9.5. with grease - see 11.2.

- Install the clutch - see 4.3. - Thinly coat the outside diameter
of the oil seal with sealant - see
11.2.

• Use the press sleeve (1)

1123 893 2400 to install the oil
seal.

Starter side - Wait about one minute, then

rotate the crankshaft.
- Remove the flywheel -
see 6.4. - Install the flywheel - see 6.4.

/
2-+--~~-
'
I
1 ------
~( A
:;:
J
~
a:
lll

• Apply puller (1) 5910 890 4400 • Position the oil seal (1) so that
(jaws 0000 893 3711 with No. 6 the clamping ring faces upwards.
profile).

021,023,025 17
5.4 Removing and Installing 5.5 Cylinder

Always check and, if necessary,

repair the fuel system, carburetor,
air filter and ignition system before
looking for faults on the engine.

- Remove the handle housing -

see 8.3.

- Remove the oil pump - see 9.5.

• Unscrew the engine pan - Remove the engine - see 5.4.

mounting screws.
- Take out the spark plug.

• Remove baffle plate.

• Pull off the worm with drive • Remove engine sideways from • Pull the manifold ( 1) off the
spring. housing. intake port.

Install in the reverse sequence. • Disconnect the impulse hose (2).

- Tighten down engine pan

mounting screws to 9.5 Nm
(7 lbf.ft) and ground wire
fastening screw to 3.5 Nm (2.6
lbf.ft).

•Takeout ground wire fastening • Pull the engine pan off the
screw. cylinder.

18 021,023,025
 - If a new cylinder has to be
installed, always fit the matching
piston. Replacement cylinders
are only supplied complete with
piston for this reason.

- Thoroughly clean all residue of

sealant from the cylinder and
engine pan mating faces.

- Apply a thin coating of sealant

to the outer diameters of the oil
• Fit the clamp (1) 1123 893 9100 seals - see 11.2. • Line up the crankshaft so that
on connecting rod of 021 up to the long crankshaft stub (1) is on
serial number X 34 944 402 to - Lubricate piston and piston ring the same side as the exhaust
prevent it slipping off the with oil. port (2).
crankshaft.
- Push piston home until ball
bearings are seated.

- On 021 up to serial number

X 34 944 402, remove the clamp
from the connecting rod.

• Lift the crankshaft and pull the • Position the piston rings so that
piston out of the cylinder. the radii at the ring gap meet at
the fixing pin in the piston groove
- Inspect ball bearings and oil when the rings are compressed.
seals and replace if necessary -
see 5.8.

~ tV,' ~

~ ~~~ ~ 7
~~~ I
- Inspect the cylinder and replace • Slide piston carefully into the • Apply a thin bead of sealant to
it if necessary. cylinder. the engine pan mating face - see
11.2.
• On easy start version, unscrew Note: The piston rings are
the decompression valve. compressed by the inner taper of Note: Follow manufacturer's
the cylinder. instructions for use of sealant.

021,023,025 19
 5.6 Piston

• Fit the engine pan so that the - Pull the piston out of the cylinder • Inspect piston rings and replace
seat (1) for the oil pump is at the - see 5.5. if necessary - see 5.7.
same side as the long crankshaft
stub (2). • Ease the hookless snap rings
out of the grooves in the piston
bosses.

to' ~ ~
!)
~

~~~ I
• On easy start version, unscrew • Use the assembly drift (2) Note: On 021, install new piston
the plug, screw home the 111 O 893 4700 to push the on crankshaft with fixed
decompression valve and tighten piston pin (1) out of the piston. connecting rod; installed original
it to 14 Nm (10.3 lbf.ft). piston on crankshaft with loose
Note: If the piston pin is stuck, tap connecting rod.
the end of the drift lightly with a
hammer. Important: Hold the • How to identify pistons:
piston steady during this process
to ensure that no jolts are Original piston "a"= 12.7 mm
transmitted to the connecting rod. New piston "a" = 12.2 mm

- Remove the piston from the

connecting rod.

- Inspect needle cage and replace

if necessary.

Note: If needle cage is press-

fitted, replace the crankshaft.

• Push the manifold on to the

intake port so that the straight
faces are in alignment.

Reassemble all other parts in the

reverse sequence.

20 021,023,025
 Note: For instructions on how to
use installing tool, see "Standard
Repairs, Troublehooting" hand-
book.

• Fit needle cage in the small end. • Fit the piston pin (1) on the
assembly drift (2) and slide it
- Oil the needle cage. into the piston (the pin slides
home easily if the piston is
warm).

• To ease assembly, heat the • Modify the sleeve of the The ring gap must be on the
piston slightly and push it over installing tool 591 0 890 221 Oas piston's vertical axis (point either
the connecting rod. shown. up or down).
a= 16 mm (11/16")
• Installed position of piston: b = 8 mm (5/16") - Install the piston - see 5.5.
1 = Arrow
2 = Long stub of crankshaft

• Push the assembly drift, small - Use installing tool (1)

diameter first, through the piston 5910 890 2210 to fit the
and small end (needle cage) and hookless snap rings.
line up the piston.

021,023,025 21
5.7 Piston Rings Crankshaft

- Pull the piston out of the cylinder

- see 5.6.

- Remove rings from piston.

• The crankshaft (1), connecting - Remove the piston - see 5.6.

rod (2) and needle bearing are
inseparable on models 023 and • Remove the retaining ring.
025 as well as model 021 from
serial number X 34 944 403.
This means the crankshaft must
always be replaced as a
complete unit.

• Use a piece of old piston ring to • On 021 up to serial number • Pull off the oil seals (1) and ball
scrape the groove clean. X 34 944 402, remove bearings (2).
connecting rod (1) from the
crankshaft (2) - see 5.9.

- When fitting a replacement

crankshaft, always install new oil
seals and ball bearings.

• Install the new piston rings in the • Heat ball bearing to approx.
grooves so that the radii face 50°C (120°F) and, with closed
upward. side facing outwards, push it on
to the crankshaft stub as far as
- Install the piston - see 5.6. stop.

22 021,023,025
 5.9 Connecting Rod
(021 up to Serial No. X 34 944 402)

Note: If the crankshaft has been Note: Cylindrical rollers are

removed, the oil seals used in available in three different
production (9639 003 1585 with toierance groups. Always replace
rigid housing) may be installed. cylindrical rollers in complete sets
of 14 to ensure that they are all
- Lubricate sealing lips of oil seals from the same tolerance group.
with grease - see 11.2.

- Remove the piston - see 5.6.

• Pull the oil seal (1) and ball

bearing (2) off the short stub of
the crankshaft.

t
• Slide oil seals over the • Remove th clamp (1) 1123 893 • Use grease, see 11.2, to stick
crankshaft stubs so that their 9100 from the connecting rod. the cylinrical rollers to the
open sides are facing the ball crankshaft.
bearings.
- Slide connecting rod into position
- Install new retaining ring in and secure it with the clamp.

e crankshaft groove.

- Install the piston - see 5.6.

- Install ball bearing and oil seal -
see 5.8.

- Install the piston - see 5.6.

• Take the connecting rod off the

crankshaft.

- Remove the cylindrical rollers

from the crankshaft.
e
021,023,025 23
5.10 Decompression Valve 6. IGNITION SYSTEM 6.1 Spark Plug Boot

Warning! Exercise extreme - Remove the air filter - see 10.1.

caution when carrying out
maintenance and repair work on - On 023 L, remove the filter base -
the ignition system. The high, see 10.2.2.
voltages which occur can cause
serious or even fatal accidents! - Pull out the shutter - see 4.3.

Troubleshooting on the ignition - Pull boot off the spark plug.

system should always begin at

I \ the spark plug. See "Standard

Repairs, Troubleshooting"
handbook.
- Remove the front handle - see
8.2.

• Use standard commercial 13 mm

socket to unscrew the
decompression valve.

- Fit new decompression valve

and torque down to 14 Nm
(10.3 lbf.ft).

- Fit the front handle.

Note: The electronic (breakerless) • Use pliers to grip the leg spring
ignition system basically consists and pull it out of the spark plug
of an ignition module (1) and boot.
flywheel (2).
- Unhook the leg spring from the
ignition lead.

- Pull spark plug boot off the

ignition lead.

- Coat end of the ignition lead

(about 20 mm/3/4") with oil.

- Fit spark plug boot over the

ignition lead.

- Use pliers to grip the end of the

ignition lead inside the spark
plug boot and pull it out.

24 021,023,025
 6.2 Ignition Lead 6.3 Ignition Module

• Pinch the hook of the leg spring - Pull the boot off the spark plug - The ignition module
into the center of the lead, i.e. see 6.1. accommodates all the
about 1O mm (3/8"} from the end components required to control
of the lead. - Remove the ignition module - ignition timing. There are two
see 6.3.2. electrical connections on the coil
body:
• Pull ignition lead out of the
guide. 1. the high voltage output (1)

2. the connector tag (2) for the

short circuit wire

Accurate testing of the ignition

module is only possible with
sophisticated test equipment. For
this reason it is only necessary to
• carry out a spark test in the work-
shop. A new ignition module must
be installed if no ignition spark is
obtained (after checking that
wiring and stop switch are in good
• Pull the lead back into the - Cut new ignition lead to length condition).
boot so that the leg spring (see parts list or cut to same
locates properly inside it (as length as old lead).
shown).
• Use pointed tool (awl or gimlet)
Important: If spark plug has a to pierce the center of the lead
separate terminal nut, make sure that is to be screwed into the
that it is properly tightened down. module.

- Fit boot on spark plug. - Pack the high voltage output with
STIHL multipurpose grease - see
- Fit the shutter - see 4.3. 11.2.

- On 023 L, fit the filter base. Important: Do not use graphite

grease (Molykote) or silicone
- Install the air filter - see 10.1. insulating paste for this job.

Reassemble all other parts in the

reverse sequence.

021,023,025 25
6.3.1 Ignition Timing 6;3.2 Removing and Installing

Ignition timing is not adjustable. • Pull the ignition module forward

a little further and turn it to
Since there is no mechanical wear unscrew the ignition lead (3)
in these systems, ignition timing from the contact pin.
cannot get out of adjustment.
However, an internal fault in the - Pull the ignition lead out of the
circuit can alter the switching point high voltage output.
in such a way that a spark test will
still show the system to be in order
although timing is outside the
permissible tolerance. This will
impair engine starting and running
behavior. · - Remove the fan housing.

• Pull short circuit wire connector

off tag on ignition module.

J ( ~~
========D~~~,o I ~ 0 a

•Takeout the screws. - If necessary, ease peg of cable

retainer out of bore.

• Remove the cable retainer.

- Pack high voltage output with

STIHL multipurpose grease -
see 11.2.

Important: Do not use graphite

grease (Molykote) or silicone
insulating paste for this job.

- Screw ignition lead into position.

- Fit short circuit wire in the

retainer.

- Pull the ignition module forward

a little.

• Take the short circuit wire (1) out

of the retainer (2).

26 021,023,025
 6.4 Flywheel

\~
I /2::::

0 \-----._~!fit(
/ ~'
~ :;
-< "'
-<
<D

ffi
-ffi
,__~~--------~ -
- Place the module in position, Removing the flywheel: Inspect the flywheel (1) and
insert the screws but do not magnet poles (2). If you find any
tighten them down yet. - Fit locking strip to block the damage, install a new flywheel.
piston - see 4.3.
• Secure ground wire (1) with
outer screw. - Remove the fan housing. Installing the flywheel:

• Slide the setting gauge (1) • Unscrew the collar nut. Important: Clean the stub of the
1111 890 6400 between the crankshaft and the flywheel hub
arms of the ignition module and - Pull off the flywheel. bore with a standard commercial,
the flywheel magnet poles. solvent-based degreasant which
contains no chlorinated or
- Press the ignition module halogenated hydrocarbons - see
against the setting gauge and 11.2.
tighten down the mounting
screws to 4 Nm (3 !bf.ft). - Fit the flywheel.

Reassemble all other parts in the Note: Check position of slot.

reverse sequence.
Assemble all other parts in the
reverse sequence.

- Tighten flywheel nut to 28.0 Nm

(20.6 lbf.ft).

Ll
Note: If the flywheel cannot be
removed by hand, screw on the
puller (1) 1116 893 0800 and tap
its end to release the flywheel.
Unscrew the puller.

021,023,025 27
7. REWIND STARTER 7.2 Rewind Spring
7.1 Routine Maintenance 7.2.1 Replacing

If the action of the starter rope Troubleshooting chart - see

becomes very stiff and the rope "Standard Repairs, Trouble-
rewinds very slowly or not com- shooting" handbook.
pletely, it can be assumed that
the starter mechanism is in order - Remove the fan housing.
but plugged with dirt. At very low
outside temperatures the lubri- - Remove the rope rotor - see
cating oil on the rewind spring may "Standard Repairs, Trouble-shoo-
thicken and cause the spring ting" handbook. Remove any
windings to stick together. This remaining pieces of spring from
has a detrimental effect on the the fan housing.
function of the starter mechanism.
In such a case it is sufficient to Note: The replacement spring co- • Position the anchor loop about
apply a few drops of paraffin mes ready for installation and is 20 mm (3/4") (dimension 'a')
(kerosine) to the rewind spring. secured with a frame. from the edge of the assembly
tool (1) 1116 893 4800.
Then carefully pull out the starter
rope several times and allow it to
rewind until its normal smooth
action is restored.
J
If clogged with dirt or pitch, the
entire starter mechanism, inclu-
ding the rewind spring, must be re-
moved and disassembled. Take
special care when removing the
spring.

Wash all parts in paraffin or white

spirit.

Lubricate the rewind spring and

starter post with STIHL special
lubricant, see 11.2, before - It should be lubricated with a few • Fit the rewind spring in the
installing. drops of STIHL special lubricant counterclockwise direction,
before installation - see 11 .2. starting from outside and
working inwards.
• The frame (1) slips off as the
rewind spring is pushed into the - Place wooden assembly block
fan housing. Engage the anchor 1108 893 4800 over the spring
loop (2) in the recess in the fan housing to simplify this operation.
housing at the same time.
- Slip the assembly tool with
Caution: The rewind spring rewind spring over the starter
may pop out and uncoil during post.
installation.

- If the rewind spring has popped

out, refit it as follows:

28 021,023,025
 7.2.2 Tensioning

- Hold the starter grip firmly to

keep the rope tensioned.

- Let go of the rope rotor and

slowly release the starter rope
so that it can rewind properly.

• Push the rewind spring into the • Make a loop in the starter rope.
fan housing and then remove the
assembly tool.

- Install the rope rotor - see

"Standard Repairs and
Troubleshooting" handbook.

- Tension the rewind spring - see

7.2.2.

• Grip the rope close to the rotor Note: The rewind spring is
and use it to turn the rope rotor correctly tensioned when the
six times clockwise. starter grip sits firmly in the rope
guide bush without drooping to
one side. If this is not the case,
tension the spring by one
additional turn.

When the starter rope is fully

extended, it must still be possible
to rotate the rope rotor at least
another half turn before maximum
spring tension is reached. If this is
not the case, pull the rope out,
hold the rope rotor steady and
take off one turn of the rope.

Do not overtension the rewind

spring as this will cause it to break.

- Fit the fan housing.

• Hold the rope rotor steady.

• Pull out the rope with the starter

grip and straighten it out.

021,023,025 29
8. AV HANDLE SYSTEM/HANDLE HOUSING
8.1 Annular Buffers

Rubber anti-vibration buffers are

installed between the handle and
engine housing, handle housing
and front handle.
Damaged rubber buffers (annular
buffers) must always be replaced.

Annular buffer in engine housing • Pry the annular buffer out of the
handle housing.
- Front handle abgebaut.

• Pry the annular buffer out of the

engine housing.

Annular buffers in front handle • Push annular buffer into the • Push the annular buffer into the
engine housing until its groove handle housing from outside until
- Remove the front handle - see engages over the housing rib. its groove (1) engages over the
8.2. edge of the housing (2).
- Fit the front handle.
• Pry both annular buffers out of - Install the handle housing - see
the front handle. 8.3.

A~S..~~--1
/

(l~
~~2
• Push home the annular buffer Annular buffer in handle housing
from the inside the front handle
until its groove (1) engages over - Remove the handle housing -
the housing rib (2). see 8.3.

• Ease the plug out of the buffer.

30 021,023,025
8.2 Front Handle 8.3 Handle Housing

- Remove the front handle -

see 8.2.

- Remove the fan housing.

- Remove the muffler - see 5.1.

- Remove the carburetor -

see 10.2.2.

• Take the lower mounting screws • Pull the lower part of the handle
out of the front handle. housing out of the front handle.

- Remove the front handle.

Reassemble in the reverse

sequence.

- Tighten down screws in annular

buffers to 3.5 Nm (2.6 lbf.ft).

- Remove lower bumper strip from • Disconnect the tank vent from
the tensioner. the stub.

• Ease plugs out of the annular

buffers.

• Take out the screws. • Pull the ground wire (1) off the
contact spring.

• Pull the short circuit wire's

contact sleeve (2) out of the
switch shaft.

021,023,025 31
 - Remove the handle housing.

- To replace, remove the annular

buffers - see 8.1 .

- Remove the switch shaft -

see 8.4.

- Remove the throttle trigger -

see 8.6.

- Remove the contact spring -

• Ease the plug out of the annular • Push the grommet out of the see 8.5.
buffer. handle housing.
- On easy start machines, remove
- Pull the ground and short circuit the manual fuel pump - see 10.6.
wires out of the bore.
Reassemble in the reverse
sequence.

cG
~? I'-
;;

"--- !
• Pry the annular buffer out of the • Pull the impulse hose off the • To fit the manifold in the handle
engine housing. stub on the handle housing. housing intake opening, wind a
piece of string (about 15 cm/ 6"
long) around the back of the
manifold flange.

• Pull the handle housing slightly • On easy start machines, pull • Place the handle housing in
forward and push the manifold manual fuel pump hose out of position and thread the string (1 ),
through the handle housing the fuel tank. fuel hose (2), ground wire (3)
opening at the same time. and short circuit wire (4) through
the openings.

32 021,023,025
 8.4 Switch Shaft

j Note: The manifold flange is thus

pulled through the handle housing
intake opening without any
damage to the manifold.

• Push the grommet for the ground - Remove the carburetor box
and short circuit wires into the cover - see 10.1 .
bore from inside.
- On 023 L, remove the filter base -
see 10.2.2.

• Pull the contact sleeve out of the

switch shaft.

[
• Connect the impulse hose to the • Push the annular buffer into the • Move the Master Control lever
stub on the handle housing. engine housing until its groove (1) until the slot in the choke
engages over the housing rib. shaft (2) and the choke rod (3)
are in line.

• Pull the ends of the string • Pull the choke rod out of the
outward. switch shaft and the choke shaft.

021,023,025 33
 8.5 Contact Spring 8.6 Throttle Trigger/
Interlock Lever

'

• Set the Master Control lever to - Remove the carburetor - see - Remove the carburetor box
the horizontal position and pry 10.2.2. cover - see 10.1.
the switch shaft out of its pivot
mount. • Pull the ground wire terminal off - On 023 L, remove the filter base -
the contact spring. see 10.2.2.

•Takeout the screw

- Lift away the handle molding.

• Pull the switch shaft out of its • Pull the contact spring out its
bore. seat in the handle housing.

Reassemble in the reverse Reassemble in the reverse

sequence. sequence.

• Lift the contact spring slightly to - Move Master Control lever to

install the switch shaft. "RUN" position.

• Pull the throttle interlock lever

out of its seat.

34 021,023,025
 - Fit the throttle trigger so that the
seat for the throttle rod points
upward.

- Fit the cylindrical pin.

- Push the throttle rod into the

throttle trigger.

• Remove throttle rod from throttle • Fit the handle molding so that
trigger. it engages behind the lugs as
shown.

- Insert screw and tighten down

to 1.6 Nm (1.2 lbf.ft).

- On 023 L, fit the filter base -

see 10.2.2.

- Fit the carburetor box cover -

see 10.1.

• Use a 4 mm (5/32") drift to drive • Press the interlock lever into the
out the cylindrical pin (1 ). slots. The torsion spring must be
under the interlock lever and
• Remove the throttle trigger (2) engage the notch.
and torsion spring (3).

• Take the torsion spring off the • Press the interlock lever (1)
throttle trigger. downward.

• Push the throttle trigger upward

and move the Master Control
lever (2) to the "Choke" position.

021,023,025 35
9. CHAIN LUBRICATION 9.2 Connector/
9.1 Pickup Body Suction Hose

Impurities gradually clog the fine

pores of the filter with minute
particles of dirt. This prevents the
oil pump from supplying sufficient
oil to the bar and chain. In the
event of problems with the oil
supply system, first check the oil
tank and the pickup body. Clean
the oil tank if necessary.

Troubleshooting chart - see

"Standard Repairs, Trouble-
shooting" handbook. • Pull the pickup body out of the - Remove the front handle -
oil suction hose. see 8.2.
- Unscrew oil filler cap and drain
the oil tank. - Wash the pickup body in white •Takeout the screw.
spirit and, if possible, blow out
Note: Collect chain oil in a clean with compressed air.
container or dispose of it properly
at an approved disposal site. - Always replace a damaged
pickup body.
- Observe safety precautions -

~~
see 1. - Flush out the oil tank.

Reassemble in the reverse

sequence.
/

~.
\~\\ \()\
• Pull the connector out of the oil
pump and suction hose.

'
r-
r- I
r- r
r- r
r- ,-
r- 1-

\J r--- r:;.
''$
~'<
i::-ffi
'~

• Use assembly hook (1) • Pull suction hose with pickup

5910 893 8800 to withdraw the body out of the oil tank.
pickup body from the oil tank.
- Remove the pickup body.
Note: Avoid stretching the oil hose.

36 021,023,025
 9.3 Vent Valve

There is a vent valve in the tank

~~
wall which keeps the internal
pressure in the oil tank equal to
atmospheric pressure.

Cleaning the valve

- Unscrew the oil filler cap.

- Drain the oil tank.

Reassemble in the reverse Note: Collect chain oil in a clean • Use a 7 mm (9/32") dia. drift to
sequence. container or dispose of it properly carefully push home the new
at an approved disposal site. valve until dimension 'a' is about
• Fit new 0-ring on connector 1 mm (3/64").
(arrow). - Observe safety precautions -
see 1. - Fit the oil filler cap.
- Tighten down screw to 2.5 Nm
(1.8 lbf.ft). - Use compressed air to blow
valve clear from the outside
inwards.

- Flush the oil tank.

- Fit the oil filler cap.

Relacing the valve

- Unscrew the oil filler cap.

• Use a 5 mm (3/16") dia. drift to

carefully drive the valve out of
the housing from inside the tank.

021,023,025 37
9.4 Worm 9.5 Oil Pump

- Remove the clutch - see 4.3. Removing • Swing lever (1) down into fork
head (2) and secure it with the
• Pull the worm and drive spring - Remove the connector - connecting pin (3).
off the crankshaft stub. see 9.2.

• Push out the lower annular

buffer.

• Take the drive spring off the • Fit lever (1) of installing tool • Swing lever upward to pull the
worm. 1123 890 2201 in the bore for oil pump out of the housing.
the annular buffer - from inside.
Reassemble in the reverse - Unscrew the oil pump from the
sequence. fork head.

• Screw fork head (1123) with Installing

threaded stem (from installing
tool) into the oil pump. • Place the oil pump in position so
that its groove (1) lines up with
the square (2) on the housing.

38 021,023,025
 10. FUEL SYSTEM
10.1 Air Filter

Dirty and clogged air filters reduce

engine power, increase fuel
consumption and make starting
more difficult.

The air filter should always be

cleaned when there is a noticeable
loss of engine power.

- Close the choke shutter.

• Place the fork head (1123) with Box filter

the straight stem (from installing
tool) in the oil pump. • Unscrew the slotted nuts.

- Fit lever in fork head and secure - Lift away the box filter.
in position.

All models except 023 L

• Press the lever down until the • Turn twist lock (1) 90 degrees • Separate the two halves of the
fork head butts against the counterclockwise. filter.
engine housing. The oil pump is
now installed at the right depth. • Lift off the carburetor box cover - Wash both halves the filter in a
(2) vertically. fresh, non-flammable cleaning
- Remove the lever. solution (e.g. warm soapy water)
- Remove all loose dirt from and then dry.
around the filter.
Note: Replace a damaged air filter
immediately.

• Push the annular buffer into the

housing until its groove engages
over the housing rib.

- Fit the connector - see 9.2.

021,023,025 39
 Install only carburetor box covers
without ribs.

Foam filter Fabric/fleece filter

• Remove the foam filter from the • Place fingers behind the filter,
filter housing. press thumbs against housing,
and swing filter toward rear
- Wash the foam filter in a fresh, handle.
non-flammable cleaning solution
(e.g. warm soapy water) and - Remove the filter.
then dry.
- Use compressed to blow out
Note: Replace a damaged foam filter from the clean air side.
filter immediately.
- If the mesh is caked with dirt or
Convert machines with foam filter no compressed air is available,
to fabric/fleece filter. wash the filter in a fresh,
non-flammable cleaning solution
- Replace the filter housing - see (e.@. warm soapy water) and
10.2.2. then dry.

Note: Replace a damaged air filter

immediately.
• If an original carburetor box
cover with ribs has to be - Push air filter onto filter housing
installed, use side cutters to until it snaps into position.
remove the ribs.
- Carburetor box cover anbauen.
- Carefully deburr the cover.

Important: Deburring is essential

to avoid damaging the filter mesh.

Note: The clearance between the

top edge of the air filter and the
carburetor box cover is only a few
millimeters.

40 021,023,025
 10.2 Carburetor
10.2.1 Leakage Test

Troubleshooting chart - see

"Standard Repairs,
Troubleshooting" handbook.

Important: If problems occur on

the carburetor or the fuel supply
system, always check and clean
the tank vent - see 10.3.

The carburetor can be tested for

leaks with the carburetor and
crankcase tester 1106 850 2905.
023L • Push fuel line with nipple onto
- Remove the carburetor box co- carburetor elbow connector.
• Unscrew twist lock (1) several ver - see 10.1.
turns counterclockwise.
- On 023 L, remove the filter base -
• Lift off the carburetor box cover see 10.2.2.
vertically.

• Grip the tab and pull the air filter

(3) out of the carburetor box.

- Knock it out or blow it out with

compressed air.

- If the mesh is caked with dirt,

wash the filter in a fresh,
non-flammable cleaning solution
(e.g. warm soapy water) and
then dry.

Note: Replace a damaged air filter

immediately. - Check tester for leaks. • Connect the tester's pressure
hose to the nipple.
• Fit the air filter in the carburetor • Pull fuel hose off the carburetor's
box cover. elbow connector.

• Fit the carburetor box cover.

• Push the fuel line (1) • Close the vent screw (1) on the
1110 141 8600 onto the nipple rubber bulb (2) and pump air into
(2) 0000 855 9200. the carburetor until the pressure
gauge (3) shows a reading of
approx. 0.8 bar (11.6 psi).

021,023,025 41
 10.2.2 Removing and Installing

If this pressure remains constant,

the carburetor is airtight. However, II, I I ~'-..di) I (
if it drops, there are two possible
causes:

1. The inlet needle is not sealing

(foreign matter in valve seat or
sealing cone of inlet needle is
damaged or inlet control lever ~
SJ
sticking). ~
,-lll
2. The metering diaphragm is
damaged. - Remove the air filter - see 10.1. • Unscrew the filter housing
locknuts.
- After completing test, open the On023 L,
vent screw and pull the fuel line • unscrew the slotted nuts (1 ). - Lift away the filter housing.
off the elbow connector.
• Remove the filter base (2).
- Push the fuel hose onto the
elbow connector.

- On 023 L, fit the filter base.

- Fit the carburetor box cover.

All models • Pull choke rod (1) out of choke

• Pull fuel hose off the carburetor's shaft (2) and switch shaft (3).
elbow connector.
- On easy start machines, ease
carburetor forward a little.

• Detach throttle rod from the • Disconnect fuel hose from the
throttle trigger. manual fuel pump.

42 021,023,025
 10.2.3 Adjustment
(except 023 Land USA)

• Remove the carburetor. • Slip the gasket off the studs. Standard setting

To readjust the carburetor, start

with the standard setting.

- Carefully screw both adjusting

screws until they are hard
against their seats.

Then make the following

adjustments:

H = High speed screw (1 ),

open 1 full turn
L = Low speed screw (2),
open 1 full turn

A slight correction to this setting

may be necessary at high altitudes
(mountains) or near sea level.

• Take the throttle rod off the • If necessary, remove the shim For corrections to high speed
throttle shaft. from the studs. screw (H):
Use a tachometer - do not
Resassemble in the reverse exceed max. permissible
sequence. engine speed.
Engine can be damaged by lack
- Fit the shim with its flat side of lubricant and overheating.
facing outward.
Maximum engine speed with bar
- Install a new gasket. and properly tensioned chain:
11,500 rpm (021)
- Tighten down locknuts to 12,500 rpm (023, 025)
2.5 Nm (1.8 lbf.ft).
Note: If no tachometer is
- On 023 L, fit a new gasket in the available, do not turn the high
filter base. speed and low speed screws
beyond the standard setting to
- On 023 L, tighten slotted nuts make the mixture leaner.
to 2 Nm (1.5 lbf.ft).

• Remove the grommet from the

adjusting screws.

021,023,025 43
 10.2.4 Adjustment
(023 L and USA)

- Check chain tension.

- Check air filter and clean

if necessary.

- Inspect the spark arresting sreen

and clean or replace if necessary.

- Start the saw -

warm up the engine.

- Adjust idle speed correctly

(chain must not rotate). This carburetor has a fixed jet in
Adjusting engine idle speed: place of the high speed adjusting
A correction at the low speed screw (H screw).
Turn high speed screw {H) and screw {L) usually necessitates a
low speed screw {L) clockwise for change in the setting of the idle Maximum engine speed is preset
leaner mixture at high altitudes or speed screw {LA). and no longer adjustable. It is only
counterclockwise for richer mixture possible to correct idling speed
at sea level. within certain limits.
Engine stops while idling:
Turn screws very slowly and Check standard setting. The carburetor guarantees an
carefully - even slight movements optimum fuel-air mixture in all
produce a noticeable change in Turn idle speed screw {LA) clock- operating conditions.
engine running behavior. wise until the chain begins to run -
then turn it back one quarter turn.
Standard setting
Note the following when making
corrections to high speed screw: Chain runs while engine is id- To•readjust the carburetor, start
ling: with the standard setting.
The setting of the high speed Check standard setting.
screw {H) affects the maximum
off-load engine speed. Turn the idle speed screw {LA) Carefully screw down the low
If the setting is too lean, the counterclockwise until the chain speed screw {L) clockwise until it
maximum permissible engine stops running - and then turn it is hard against its seat. Then open
speed will be exceeded and about another quarter turn in the it one full turn.
increase the risk of engine same direction.
damage. - Check chain tension.

Erratic idling behavior, - Check air filter and clean if

poor acceleration necessary.
Idle setting too lean.
- Inspect the spark arresting
Turn the low speed screw {L) screen and clean or replace if
counterclockwise until the engine necessary.
runs and accelerates smoothly.
- Start the saw -
warm up the engine.

- Adjust idle speed correctly

(chain must not rotate).

44 021,023,025
 10.3 Tank Vent

Correct operation of the carburetor

is only possible if atmospheric 1------=II
pressure and internal fuel tank fO
pressure are equal at all times.
This is ensured by the tank vent. 2 --------------¾! I
Important: If problems occur on
the carburetor or the fuel supply I I
2---~/'lll system, always check and clean ;-----

LA
the tank vent.
1 ------=ii
Check function by performing
pressure and vacuum tests on • Use a 3 mm (1/8") dia. drift to
Adjusting engine idle speed the tank via the fuel hose. push the grub screws (1) out
A correction at the low speed of the hose (2).
screw (L) usually necessitates a - Remove the carburetor box
change in the setting of the idle cover - see 10.1. - Wash all parts in fresh white
speed adjusting screw (LA). spirit and blow clear with
- On 023 L, remove the filter compressed air.
Note: Turn screws very slowly and base - see 10.2.2.
carefully - even slight movements Reassemble in reverse sequence.
produce a noticeable change in
engine running behavior.

Engine stops while idling:

Check standard setting. ,

Turn idle speed screw (LA) clock-

wise until the chain begins to run -
then turn it back one quarter turn.

Chain runs while engine is

idling:
Check standard setting.

Turn the idle speed screw (LA)

counterclockwise until the chain
stops running - and then turn it
about another quarter turn in the
same direction.

Erratic idling behavior, poor

acceleration -
even though low speed screw in
one turn open
Idle setting too lean.

Turn the low speed screw (L)

counterclockwise until the engine
runs and accelerates smoothly.

• Remove the vent from the stub • Use a drift to position the grub
on the fuel tank. screws as shown in the
illustration.
a = approx. 20 mm (3/4")

t
021,023,025 45
10.4 Pickup Body 10.5 Suction Hose

The diaphragm pump draws fuel

out of the tank and into the
carburetor via the fuel hose. Any
impurities mixed with the fuel are
retained by the pickup body (filter).
The fine pores of the filter
event-ually become clogged with
minute particles of dirt. This
restricts the passage of fuel and
results in fuel starvation.

Important: In the event of trouble

with the fuel supply system, • Use hook (1) 591 O 893 8800 to - Remove the handle housing -
always check the fuel tank and pull the pickup body out through see 8.3.
the pickup body first. Clean the the filler opening.
fuel tank if necessary. - Remove the pickup body -
Note: Do not stretch the suction see 10.4.
hose.
Cleaning the fuel tank: - Pry suction hose flange out of
the fuel tank.
- Unscrew the filler cap and drain
the tank. • Pull the suction hose out of
the tank.
Note: Observe safety precautions -
see 1. Reassemble in the reverse
sequence.
- Pour a small amount of clean
gasoline into the tank.

- Close the tank and shake the

saw vigorously.

- Open the tank again and drain it.

• Pull the pickup body off the fuel
Note: Dispose of fuel properly. hose.

- Replace the pickup body.

Pickup body
Reassemble in the reverse
- Unscrew the fuel filler cap and sequence. - Coat the hose flange with a little
remove it together with the cap oil to simplify installation.
retainer, if fitted.

• Straight side (1) of hose

flange must be parallel to tank
joint (2).

46 021,023,025
 10.6 Manual Fuel Pump 10.6.1 Fuel Hoses

e Easy start machines only - Disconnect the hoses from the

fuel pump - see 10.6.
- Remove the air filter - see 10.1.
- Remove the filter housing -
- Take out the shutter - see 4.3. see 10.2.2.

- Pull boot off the spark plug. - Pull off the tank vent -
see 10.3.

• Carefully squeeze the retaining

tabs.

- Pull the fuel pump out of its seat

in the handle housing.

Reassemble in the reverse

sequence.

- Push home the fuel pump (short

intake stub facing the air filter)
until retaining tabs snap into
position.

- Connect carburetor suction hose

to the short stub.

• Carefully push cover, if fitted, • Pull the suction hose off the
with thumb in direction of arrow carburetor stub.
until it is released from its seat.
- Pull the suction hose out of the
- Remove the cover. bore in the handle housing.

- If necessary, pull the helical

spring out of the suction hose.

Note: The helical spring must be

fitted to prevent the hose bend
kinking and restricting its cross
section.

• Disconnect hoses from the • Slide the cover (1) under the top
connectors. retaining tab (2) and fit the pin
(3) in the bore in the handle
housing.

021,023,025 47
 10.7 Fuel Tank

Fuel tank and engine housing are • Use hook (1) 5910 893 8800 to
a single unit. pull pickup body out of the fuel
tank.
- Remove the engine - see 5.4.
Note: Do not stretch the suction
- Remove the chain tensioner - hose.
see 4.5 and 4.6.

- Remove the chain brake -

see 4.4.2.

• Pull the return hose (1) out of

the retainers (2).

• Pull the return hose out of the

grommet (3) and the bore in the
handle housing.

- Check grommet and replace if

necessary.

Note: Grommet is essential to

provide an effective seal.

Reassemble in the reverse

sequence.

• Disconnect the short circuit • Disconnect pickup body from the

wire (1 ). suction hose.

• Take out the screws (2).

• Remove the ignition module (3).

- Unscrew the fuel filler cap and - Pry the suction hose flange out
remove with cap retainer, if fitted. of the fuel tank.

• Pull out the suction hose.

48 021,023,025
 • To install engine housing in a
machine with a quick chain
tensioner, use stud puller (1)
5910 893 0501 to slowly
unscrew the rear collar screw.

Note: Thread in engine housing

can be damaged if stud puller is
turned too fast.

• Pull out the oil pump suction Reassemble in the reverse

hose with pickup body. sequence.

• Position ground wires, short

circuit wire and ignition lead in
the housing slots.

- After assembling, set distance

between ignition module and
flywheel - see 6.3.2.

- Coat the fuel hose flange with a

little oil to simplify installation.

- Straight side of hose flange

must be parallel to tank joint.

• Remove the spiked bumper, if - Apply a little oil to the thread of

fitted. the new or original collar screw.

• Insert collar screw in the bore of

the replacement engine housing
and turn it counterclockwise until
it engages the thread.

- Then screw it home clockwise

amd torque down to approx.
8.0 Nm (5.9 lbf.ft).

- Tighten down mounting screws

on spiked bumper to 3.7 Nm
(2.8 lbf.ft).

• On machines with quick chain Note: Replacement engine

tensioner, remove the stiffener housings are supplied with two
(1) and take out the rear collar collar screws of the same length.
screw (2).

021,023,025 49
11. Special Servicing Tools and Aids
11.1 Special Servicing Tools

No. Part Name Part No. Application Rem.

1 Locking strip 0000 893 5903 Blocking crankshaft

2 Press sleeve 1123 893 2400 Fitting oil seal
3 - Guide sleeve 1123 894 7700 - (ignition side only)
4 Puller 5910 890 4400 Removing oil seals 1)
5 - Jaws (No. 6) 0000 893 3711
6 Puller 1116 893 0800 Removing flywheel
7 Crimping tool 5910 890 8210 Attaching connectors to
electrical wires
8 Assembly drift 1110 893 4700 Removing and fitting
piston pin
9 Carburetor and crankcase 1106 850 2905 Testing carburetor and
tester engine for leaks
10 - Nipple 0000 855 9200
11 - Fuel hose 1110 14 1 8600
12 Vacuum pump 0000 850 3501 Testing engine for leaks
13 Sealing plate 0000 855 8106 Sealing exhaust port for
leakage test
14 - Flange 1123 855 4200
15 - Sleeves 1123 851 8300
16 Test flange 111 8 850 4200 Leakage test
17 Setting gauge 1111 890 6400 Setting air gap between
ignition module and flywheel
18 Socket, 13 mm 5910 893 5608 Flywheel nut
19 Socket, 19 mm 5910 893 5612 Clutch

20 Torque wrench 5910 890 0301 O.5-18Nm 2)

(0.4 - 13.5 lbf.ft)
5910 890 0302 3)
21 Torque wrench 5910 890 0311 6 bis 80 Nm 2)
(4.4 - 60 lbf.ft)
5910 890 0312 3)
22 Spline screw socket T27x125 0812 542 21 04 IS screws
23 Hook 5910 893 8800 Removing pickup bodies
24 Installing tool 5910 890 2210 Installing hookless snap rings
in piston
25 Assembly tube 1117 890 0900 Attaching brake spring
26 T-handle screwdriver QI-T27x150 5910 890 2400 For all IS screws 4)
27 Stud puller M8 5910 893 0501 Removing guide bar
mounting studs

50 021,023,025
No. Part Name Part No. Application Rem.

28 Clamp 1123 893 9100 Holding conrod bearing 5)

29 Installing tool 1123 890 2201 Removing/installing oil pump
30 Installing tool 1116 893 4800 Refitting rewind spring
31 Assembly stand 5910 890 3100 Holds chainsaw for
repairs
32 - Clamping bar 5910 890 2000

Remarks:
1) Equivalent to puller 0000 890 4400, but with longer spindle 5910 890 8400.
2) DG screws must always be tightened with a torque wrench
3) Wrench has optical/acoustic signal
4) Only use for releasing DG screws
5) 021 up to serial No. X 34 944 402 only

021,023,025 51
11.2 Servicing Aids

No. Part Name Part No. Application

1 Lubricating grease 0781 120 1111 Oil seals, oil pump drive,
(370 g/13 oz tube) chain sprocket bearing, chain tensioner,
cylindrical rollers

2 Standard commercial, Cleaning crankshaft stub and

solvent-based degresant flywheel taper
containing no chlorinated
or halogenated hydrocarbons

3 STIHL special lubricant 0781 4171315 Bearing bore in rope rotor,

rewind spring in fan housing

4 Ignition lead HTR, 0000 930 2251

10 m (33')

5 Dirko sealant, 0783 830 2120 Engine pan, oil seals (outside dia.)
(100 g/3 1/2 oz tube)

6 Graphite grease Peg on pawl

7 Molykote grease Sliding and bearing points on brake band

8 STIHL Bioplus 0781 516 3331 Protects brake band against corrosion
(1 1/34 fl.oz bottle)

l
52 021,023,025