044 Stihl Chainsaw Service Repair Manual

The Stihl 044 chainsaw is a professional-grade power tool known for its reliability and performance in demanding cutting applications. This comprehensive service and repair manual provides detailed instructions for maintenance, troubleshooting, disassembly, and reassembly of the Stihl 044 chainsaw. It covers engine systems, fuel system, ignition system, chain brake, lubrication, and electrical components to ensure proper servicing and safe operation.

1. Safety Precautions 2. Specifications 3. Tools Required 4. Maintenance Schedule 5. Engine System Service 6. Fuel System Repair 7. Ignition System Service 8. Chain & Bar Maintenance 9. Chain Brake System 10. Lubrication System 11. Troubleshooting Guide

Safety Precautions

Before performing any service or repair, always prioritize safety to prevent injury and damage to the chainsaw.

Precaution	Description
Disconnect Spark Plug	Always remove spark plug wire before servicing to prevent accidental starting.
Wear Protective Gear	Use safety glasses, gloves, and hearing protection during repairs.
Work in Well-Ventilated Area	Service in open space to avoid inhalation of fuel vapors.
Secure Chainsaw	Clamp saw securely in vise or on stable workbench.
Use Proper Tools	Employ recommended Stihl tools or equivalents to avoid damage.
Handle Fuel Safely	Drain fuel tank before disassembling fuel system components.
Chain Tension	Ensure chain is properly tensioned and sharpened before test runs.
Follow Torque Specifications	Use torque wrench for critical fasteners to prevent over-tightening.
Inspect for Wear	Check all parts for excessive wear or damage before reassembly.
Test Operation Safely	After repair, test in clear area away from people and obstacles.

Specifications

Technical specifications for the Stihl 044 chainsaw model.

Engine Type: 2-stroke, single cylinder, air-cooled.
Displacement: 70.7 cc (4.3 cu. in.).
Power Output: 4.4 kW (6.0 hp).
Fuel Capacity: 0.75 L (25.4 fl. oz.).
Oil Tank Capacity: 0.33 L (11.2 fl. oz.).
Ignition System: Electronic, capacitor discharge (CDI).
Carburetor: Walbro or Zama diaphragm type.
Bar Length Range: 40 cm (16") to 63 cm (25").
Chain Pitch: 3/8" or .325".
Weight (Powerhead): 6.2 kg (13.7 lbs).

Tools Required

Specialized and standard tools needed for servicing the Stihl 044.

Stihl piston stop tool (or equivalent) for cylinder work.
Flywheel puller (Stihl tool # 1129 893 4500).
Clutch removal tool (Stihl tool # 0000 893 4302).
Spark plug wrench (included with saw).
Torque wrench (range 5-50 Nm).
Standard metric socket set (8mm-13mm).
Screwdrivers (flathead and Phillips).
Compression tester (for engine diagnosis).
Multimeter (for ignition system testing).
Carburetor adjustment tool (splined).

WARNING! Using incorrect tools can damage components and void warranty.

Maintenance Schedule

Recommended service intervals for optimal performance and longevity.

Daily: Clean air filter, check chain tension and sharpness, inspect for loose fasteners.
Weekly: Clean cooling fins, check spark plug condition, clean chain brake band.
Monthly: Replace fuel filter, clean spark arrestor screen, check anti-vibration elements.
Every 3 Months: Replace air filter, inspect fuel lines for cracks, check clutch drum and sprocket.
Every 6 Months: Clean carburetor, replace spark plug, check cylinder compression.
Annually: Replace fuel line and impulse line, inspect piston and cylinder through exhaust port.

CAUTION! Service intervals may vary based on usage intensity and operating conditions.

Engine System Service

Procedures for servicing the engine cylinder, piston, crankshaft, and bearings.

Disassembly: Remove top cover, air filter, carburetor, muffler, and cylinder cover. Use piston stop to hold crankshaft, remove clutch and flywheel. Unbolt cylinder and carefully lift off. Inspect piston rings, cylinder walls for scoring.

Reassembly: Install new gaskets, lubricate piston rings with two-stroke oil. Align piston ring gaps with locating pins. Torque cylinder bolts to 10 Nm (88 in-lb) in crisscross pattern. Reinstall flywheel (torque 40 Nm) and clutch (torque 35 Nm). Set ignition coil air gap to 0.3 mm (0.012").

Fuel System Repair

Servicing the fuel tank, lines, filter, and carburetor.

Drain fuel from tank completely.
Remove fuel tank cover and disconnect fuel line from carburetor.
Replace fuel filter inside tank using wire hook.
Inspect fuel line and impulse line for cracks or stiffness; replace if necessary.
Remove carburetor by loosening mounting nuts and disconnecting throttle linkage.
Clean carburetor with compressed air; replace diaphragm and gasket kit if leaking.
Reinstall with new gaskets; adjust idle (L) and high-speed (H) screws to factory settings: L=1 turn out, H=1 turn out as starting point.

Tip: Always use fresh, properly mixed fuel (50:1 ratio with Stihl HP Ultra oil).

Chain & Bar Maintenance

Proper care for cutting chain, guide bar, and sprocket.

Supports standard 3/8" pitch chains and .325" pitch options.

Remove bar and chain: Loosen bar nuts, remove clutch cover.
Clean bar groove and oil holes with wire brush.
Inspect bar for straightness and wear; file rails if uneven.
Sharpen chain with round file (5.5 mm for 3/8" chain) at 30° angle.
Check drive sprocket for wear; replace if teeth are hooked.
Reinstall with proper tension: chain should snap back when pulled from bar.
Adjust oiler flow via screw on bottom of saw (clockwise to increase).

WARNING! Always wear cut-resistant gloves when handling chain. Ensure chain brake is functional before use.

Chain Brake System

Service procedures for the manual/inertia activated chain brake.

Component	Inspection	Action
Brake Band	Check for wear or glazing	Replace if thickness < 1.5 mm
Brake Handle	Test engagement and return	Lubricate pivot points
Inertia Spring	Ensure proper tension	Replace if deformed
Clutch Cover	Check for cracks	Replace if damaged
Activation Test	With saw off, engage brake	Chain should lock completely

Lubrication System

Maintaining the automatic chain oiling system.

Unplug before cleaning. Use dry cloth only; no liquids or aerosols.

Clean oil tank screen and breather hole.
Check oil pump drive connection to crankshaft.
Test oil flow: Run saw at high speed with bar tip near cardboard; should produce oil line.
Adjust oil flow via screw on bottom of saw (clockwise increases).
Replace oil lines if cracked or leaking.

CAUTION! Use only Stihl chain oil or equivalent biodegradable oil. Never run saw without bar oil.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, flooded, fuel issue	Check spark plug, dry cylinder, clean carburetor.
Engine runs poorly	Clogged air filter, carb adjustment	Clean/replace filter, adjust L and H screws.
Loss of power	Exhaust clogged, compression low	Clean spark arrestor, check piston/cylinder.
Chain won't oil	Clogged oil passages, pump failure	Clean bar groove, check pump drive.
Chain brake not engaging	Worn brake band, weak spring	Replace brake band and spring.
Excessive vibration	Loose components, worn AV mounts	Tighten fasteners, replace anti-vibration elements.
Overheating	Dirty cooling fins, lean mixture	Clean fins, enrich carburetor settings.
Clutch slipping	Worn clutch shoes, weak springs	Replace clutch assembly.

Reset: For electronic ignition issues, disconnect spark plug wire for 30 seconds to reset module.

Service Support: For genuine Stihl parts and technical assistance, contact authorized Stihl dealers or visit www.stihlusa.com.