Stihl 020 AV Manual

The Stihl 020 AV is a professional-grade gasoline-powered chainsaw featuring anti-vibration (AV) technology, designed for demanding forestry and arborist work. This manual covers safety procedures, technical specifications, operation instructions, maintenance guidelines, and troubleshooting for optimal performance and user safety. Below are key sections for safe operation, features, assembly, maintenance, and problem resolution.

Features at a Glance

Key components: Anti-vibration handle system, QuickStop chain brake, decompression valve, side-access chain tensioner, electronic ignition, and automatic oiler.

Feature	Description
Anti-Vibration System	Reduces operator fatigue during extended use
QuickStop Chain Brake	Stops chain rotation in kickback situations
Decompression Valve	Easier starting by reducing cylinder pressure
Side-Access Tensioner	Allows chain adjustment without tools
Electronic Ignition	Reliable spark generation in all conditions
Automatic Oiler	Lubricates chain and bar during operation
Throttle Lockout	Prevents accidental throttle activation
Chain Catcher	Stops broken chain from striking operator
Right-Hand Guard	Protects hand from debris and chain
Spark Arrestor	Prevents emission of burning particles

Safety Instructions

Read all instructions before operation. Wear proper PPE.

1. Personal Protective Equipment: Wear safety glasses, hearing protection, gloves, chainsaw chaps, and steel-toe boots.
2. Work Area Safety: Clear area of bystanders, especially children. Maintain secure footing.
3. Chain Brake Test: Test QuickStop function before each use by engaging brake with throttle released.
4. Kickback Prevention: Keep saw body close to your body; never cut with tip of bar.

WARNING! Chainsaws are dangerous tools. Failure to follow safety instructions can result in serious injury or death. Never operate when tired or under influence of drugs/alcohol.

Assembly & Preparation

Unpack and inspect all components. Assemble before first use.

1. Attach Guide Bar: Place bar on studs, align chain with sprocket, adjust tension.
2. Install Chain: Ensure cutting teeth face forward on top of bar. Adjust tension.
3. Fuel Mix: Prepare 50:1 gasoline to 2-stroke oil mixture. Use Stihl HP Ultra or equivalent.
4. Fill Tanks: Add fuel to fuel tank, chain oil to oil tank. Wipe away spills.
5. Starting Procedure: Set master control lever to cold start position, pull starter cord.

CAUTION! Use only Stihl-approved replacement parts. Improper assembly can cause malfunction.

Technical Specifications

• Engine Type: Single cylinder, 2-stroke, air-cooled.
• Displacement: 35.2 cc (2.15 cu in).
• Power Output: 2.0 kW (2.7 hp).
• Fuel Capacity: 0.55 L (18.6 fl oz).
• Oil Capacity: 0.26 L (8.8 fl oz).
• Guide Bar Lengths: 12" to 16" (30-40 cm).
• Chain Pitch: 3/8" PMM or .325".
• Weight (without bar/chain): 4.6 kg (10.1 lbs).
• Sound Pressure Level: 106 dB(A).
• Vibration Level: 4.5 m/s² (front handle), 6.5 m/s² (rear handle).

Controls & Operation

Master Control Lever: Combines stop switch, choke, and run positions. Throttle Trigger: Controls engine speed. Throttle Lockout: Must be depressed to activate throttle. Chain Brake Lever: Manual engagement; also activates automatically during kickback.

Starting Procedure: 1. Engage chain brake. 2. Set master control to cold start. 3. Press decompression valve. 4. Pull starter cord until engine fires. 5. Move control to run position. 6. Pull starter cord to start.

Cutting Techniques: Use lower quadrant of bar for bucking. Let saw do the work; don't force. Maintain proper chain tension and lubrication.

Fuel & Lubrication

Fuel: 50:1 mix of unleaded gasoline (min 89 octane) with Stihl 2-stroke oil. Chain Oil: Use Stihl chain oil or equivalent for temperatures above 14°F (-10°C).

1. Mix fuel in approved container, not in saw tank.
2. Fill fuel tank on level surface, avoiding spills on plastic components.
3. Check oiler flow: Run saw at full throttle over light-colored surface; look for oil line.
4. Adjust oiler if necessary using screw on bottom of saw.

Tip: Use fresh fuel (less than 30 days old). Stale fuel causes starting problems.

Chain & Bar Maintenance

Daily maintenance ensures optimal cutting performance and safety.

1. Chain Sharpening: File at 30° angle with round file. Maintain consistent depth gauges.
2. Chain Tension: Adjust when chain sags from bar rails. Should snap back when pulled.
3. Bar Maintenance: Clean bar grooves weekly. Flip bar monthly for even wear.
4. Sprocket Inspection: Replace if teeth are hooked or worn.
5. Chain Replacement: Replace when stretched beyond adjuster range or teeth shortened.

WARNING! Always wear gloves when handling chain. Disconnect spark plug before maintenance.

Engine Maintenance

Air Filter: Clean weekly; replace when damaged. Spark Plug: Clean and gap to 0.020" (0.5 mm); replace annually. Cylinder Fins: Keep clean for proper cooling. Spark Arrestor: Clean monthly with wire brush.

Storage Guidelines

Long-term storage preparation prevents fuel system damage.

1. Drain fuel tank and run engine until it stops.
2. Remove spark plug, add 1 tsp of oil through spark plug hole.
3. Pull starter cord slowly to distribute oil.
4. Clean entire saw, especially cooling fins and air filter.
5. Store in dry place, covered to prevent dust accumulation.

CAUTION! Never store with fuel in tank for more than 30 days. Fuel degrades and damages carburetor.

Warranty Information

Stihl 020 AV includes 1-year commercial warranty, 2-year residential warranty from date of purchase. Warranty covers defects in materials and workmanship. Not covered: normal wear, misuse, improper maintenance, or use of non-Stihl parts. For warranty service, contact authorized Stihl dealer with proof of purchase. For support, visit www.stihlusa.com or contact 1-800-467-8445.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Old fuel, flooded, no spark	Use fresh fuel; wait 10 min if flooded; check spark plug.
Engine starts then dies	Clogged filter, fuel line	Clean/replace air filter; check fuel line for cracks.
Chain doesn't turn	Brake engaged, clutch worn	Disengage chain brake; inspect clutch springs/shoes.
Chain throws oil	Over-oiling, wrong oil	Adjust oiler screw; use proper chain oil viscosity.
Excessive vibration	Loose components, AV mounts	Tighten all bolts; inspect anti-vibration mounts.
Poor cutting performance	Dull chain, wrong filing angle	Sharpen chain properly; check depth gauge height.
Chain comes off bar	Loose tension, worn bar	Adjust tension; inspect bar for wear/damage.

Service Intervals: Professional servicing recommended every 50 operating hours or annually.

Authorized Service: 1-800-467-8445; www.stihlusa.com