Old Stihl Manual

The Old Stihl Manual covers classic Stihl chainsaw models, providing essential information on safety, operation, maintenance, troubleshooting, and parts identification for vintage Stihl equipment. This manual is designed for owners of older Stihl chainsaws to ensure proper handling, maximize performance, and maintain the longevity of their tools. Below are key sections covering safety precautions, features, operation, maintenance, and technical specifications.

Safety Precautions

Essential safety guidelines to prevent injury and damage when operating classic Stihl chainsaws.

Precaution	Description
Personal Protective Equipment	Always wear safety glasses, hearing protection, gloves, and chainsaw chaps.
Safe Starting	Place saw on ground, secure footing, and engage chain brake before starting.
Kickback Awareness	Hold saw firmly with both hands; avoid contact with upper bar tip.
Work Area Safety	Clear area of obstacles, ensure no bystanders within 15 feet.
Fuel Handling	Refuel in well-ventilated area, away from ignition sources; use approved fuel mix.
Chain Brake Use	Test chain brake regularly; engage when not actively cutting.
Transport Safety	Engage chain brake and install scabbard when carrying saw.
Maintenance Safety	Disconnect spark plug before performing maintenance.
Environmental Conditions	Do not operate in wet conditions or poor visibility.
Emergency Procedures	Know how to stop engine quickly and apply first aid if needed.

Features & Components

Key components of classic Stihl chainsaw models.

1. Engine: Two-stroke air-cooled engine with manual choke and primer bulb.
2. Guide Bar: Laminated steel bar in various lengths (14" to 20").
3. Saw Chain: Oregon or Stihl chain with specific pitch and gauge.
4. Chain Brake: Inertia-activated safety brake.
5. Throttle Trigger: Lockout safety feature to prevent accidental acceleration.
6. Fuel Tank: Integrated tank for gasoline/oil mixture.
7. Oil Tank: Separate reservoir for chain lubrication.
8. Air Filter: Foam or felt filter for engine protection.
9. Spark Arrestor: Muffler screen to prevent fire hazards.
10. Decompression Valve: On some models for easier starting.

WARNING! Always inspect components for wear or damage before operation.

Operation Instructions

Proper starting, cutting, and shutdown procedures for classic Stihl chainsaws.

1. Pre-Start Check: Verify chain tension, lubrication, and fuel levels.
2. Starting Procedure: Set master control to cold start position, engage chain brake, pull starter cord until engine fires.
3. Warm-Up: Allow engine to idle for 30 seconds before applying load.
4. Cutting Techniques: Use proper stance, let chain do the work, avoid pinching.
5. Chain Lubrication: Ensure oiler is functioning; check oil level frequently.
6. Shutdown: Allow engine to idle briefly, then move master control to stop position.
7. Post-Operation: Clean saw, check for loose parts, store properly.

CAUTION! Never operate chainsaw with loose or damaged chain.

Maintenance Schedule

• Daily: Clean air filter, check chain tension, inspect bar for wear.
• Weekly: Clean spark arrestor screen, check spark plug condition.
• Monthly: Clean fuel filter, replace air filter if damaged.
• Seasonally: Replace fuel lines if cracked, clean carburetor.
• Annually: Check piston and cylinder for scoring, replace worn sprocket.
• Chain Sharpening: Sharpen when cutting produces fine dust instead of chips.
• Bar Maintenance: File bar rails, rotate bar regularly for even wear.
• Storage: Drain fuel or add stabilizer for long-term storage.

Technical Specifications

Common specifications for classic Stihl models (e.g., 028, 038, 044).

Specification	Details
Engine Displacement	45cc to 70cc depending on model
Power Output	2.5 to 5.0 horsepower
Fuel Capacity	0.5 to 0.8 liters
Oil Capacity	0.2 to 0.3 liters
Weight (without bar)	5.0 to 6.5 kg
Chain Pitch	3/8" or .325"
Chain Gauge	0.050" or 0.058"
Bar Length Options	14" to 20"
Ignition System	Electronic ignition (CDI)
Fuel/Oil Ratio	50:1 (modern) or 40:1 (older models)

Chain & Bar Assembly

Proper installation and tensioning of chain and guide bar.

1. Remove side cover: Loosen nuts with combination wrench.
2. Install bar: Align bar with tensioning pin and oiler hole.
3. Install chain: Place chain over bar with cutting teeth facing forward.
4. Tension chain: Adjust tensioning screw until chain snaps back when pulled from bar.
5. Secure cover: Tighten nuts while lifting bar tip upward.
6. Final check: Chain should move freely without binding.

Tip: Always wear gloves when handling chain to prevent cuts.

Fuel & Lubrication

Proper fuel mixture and lubrication requirements for classic two-stroke engines.

1. Fuel Mix: Use 89+ octane gasoline with ISO-L-EGD or JASO FD rated two-stroke oil.
2. Mixing Ratio: Follow manufacturer specification (typically 50:1 for newer oils).
3. Mixing Procedure: Add oil to can first, then gasoline; shake thoroughly.
4. Chain Oil: Use proper bar and chain oil; vegetable-based oils available.
5. Storage: Use fuel stabilizer if storing over 30 days.
6. Contamination: Never use fuel older than 60 days; discard properly.

WARNING! Never use automotive motor oil or diesel fuel in chainsaw.

Troubleshooting Guide

Problem	Possible Cause	Solution
Engine won't start	Old fuel, flooded engine, bad spark plug	Use fresh fuel, wait 15 minutes if flooded, replace spark plug
Engine runs poorly	Clogged air filter, dirty carburetor	Clean/replace air filter, clean carburetor jets
Chain won't turn	Brake engaged, clutch worn, chain bound	Disengage brake, inspect clutch, free chain from cut
Excessive vibration	Loose components, unbalanced chain	Tighten all fasteners, balance chain or replace
Chain throws oil	Overfilled oil tank, wrong oil viscosity	Drain excess oil, use proper bar oil
Chain dulls quickly	Cutting dirty wood, improper filing	Avoid soil contact, sharpen at correct angle
Overheating	Dull chain, insufficient lubrication	Sharpen chain, check oiler function

Parts Identification

Common replacement parts for classic Stihl chainsaws.

• Ignition Components: Spark plug (Bosch WSR6F or equivalent), ignition coil, flywheel.
• Fuel System: Carburetor kit, fuel filter, fuel lines, primer bulb.
• Air System: Air filter, filter cover, intake boot.
• Cutting System: Guide bar, saw chain, drive sprocket, clutch assembly.
• Engine Components: Piston rings, cylinder, crankshaft bearings.
• Controls: Throttle cable, choke lever, master control lever.
• Fasteners: Bar nuts, side cover screws, antivibration mounts.

Note: Always use genuine Stihl parts or certified equivalents.

Warranty & Support

Classic Stihl chainsaws may no longer be under warranty but support is available.

For technical assistance, parts identification, or service manuals:

• Contact authorized Stihl dealers for vintage parts.
• Visit www.stihlusa.com for dealer locator and resources.
• Reference model number (found on serial plate) when ordering parts.
• Some independent shops specialize in vintage chainsaw restoration.

Disclaimer: This manual is for reference only. Always consult professional for major repairs.