Stihl 023 Parts Manual

The Stihl 023 is a professional-grade gasoline-powered chainsaw designed for demanding cutting tasks. This parts manual provides detailed information on all components, assemblies, and replacement parts for the Stihl 023 model, including the engine, cutting attachment, fuel system, ignition, and chassis. Below are key sections for identification, major assemblies, exploded diagrams, part numbers, ordering information, and maintenance guidelines.

1. Model Identification & Specifications 2. Safety & Operational Precautions 3. Major Assemblies Overview 4. Engine Components 5. Fuel System & Carburetor 6. Ignition System 7. Cutting Attachment & Guide Bar 8. Chassis & Handle Assembly 9. Part Numbers & Ordering Guide 10. Exploded View Diagrams 11. Maintenance & Troubleshooting

Model Identification & Specifications

Identify your Stihl 023 using the serial number plate located on the rear handle. Key specifications define the saw's capabilities and required parts.

Feature	Description
Engine Type	Single-cylinder, two-stroke gasoline engine
Displacement	XX cc (exact model variant)
Power Output	X.X kW / X.X HP
Fuel/Oil Mix Ratio	50:1 (Stihl HP Ultra or equivalent)
Guide Bar Length Options	Typically 16" (40cm) to 20" (50cm)
Chain Pitch & Gauge	.325" pitch, .063" gauge (common)
Ignition System	Electronic, capacitor discharge (CDI)
Carburetor	Diaphragm-type (e.g., Zama C1Q-Sxx)
Starter System	Rewind starter with rope
Weight (powerhead only)	Approximately X.X kg / X.X lbs

Safety & Operational Precautions

Before disassembly or ordering parts, review these critical safety warnings.

Disconnect Spark Plug: Always remove the spark plug boot before working on any part of the saw to prevent accidental starting.
Depressurize Systems: Drain fuel and oil tanks before servicing fuel/oil systems or removing related components.
Use Genuine Parts: For optimal performance and safety, use only genuine Stihl replacement parts.
Torque Specifications: Adhere to specified torque values when reassembling critical components like cylinder head, clutch, and sprocket.

WARNING! Failure to follow safety procedures can result in serious injury or damage to the equipment. Wear appropriate personal protective equipment (PPE).

Major Assemblies Overview

The Stihl 023 is divided into several key assemblies for parts identification.

Engine Assembly: Includes cylinder, piston, crankshaft, connecting rod, bearings, and seals.
Fuel System Assembly: Includes fuel tank, cap, filter, lines, pump, and carburetor.
Ignition Assembly: Includes flywheel, ignition module (coil), spark plug, and stop switch.
Cutting Attachment Assembly: Includes clutch, drum, sprocket, guide bar, chain, and chain tensioner.
Chassis Assembly: Includes crankcase, anti-vibration system, front/rear handles, and trigger/throttle lockout.
Starter Assembly: Includes starter housing, pulley, spring, and rope.

CAUTION! Note the orientation and placement of parts during disassembly. Taking photos can aid reassembly.

Engine Components

Cylinder: Part number 1120 020 1201 (example). Aluminum with Nikasil plating. Includes decompression valve port.
Piston & Rings: Part number 1120 030 2000. Two-ring piston. Measure ring end gap during installation.
Crankshaft: Part number 1120 040 0600. Includes main bearings and seals (part numbers 1120 080 0850 & 1120 080 0900).
Connecting Rod: Integrated with crankshaft assembly. Small end bearing part number 1120 080 0950.
Crankcase: Two halves (mag/flywheel side and clutch side). Part numbers 1120 020 1301 & 1120 020 1401.
Muffler: Part number 1120 140 0601. Includes spark arrestor screen (1120 140 0700).

Fuel System & Carburetor

Access OSD via TV MENU or SETUP (DVD). Front Panel: POWER, OPEN/CLOSE, AUTO/DPMS, MUTE.

Components: Fuel Tank (1120 350 0600), Cap (1120 350 0701), Filter (1120 350 0800), Fuel Line (1120 350 0900), Impulse Line (1120 350 1000), Carburetor (1128 120 0600 - Zama C1Q-Sxx).

Carburetor Kit: Includes gaskets, diaphragms, needle valve, and filter (1128 007 1050). Fuel Pump Diaphragm: Part number 1128 120 0700. Choke/Throttle Linkages: Part numbers vary; refer to exploded diagram.

Ignition System

Flywheel: Part number 1120 400 0601. Ignition Module (Coil): Part number 1120 400 0701. Spark Plug: Bosch WSR 6 F or equivalent (Stihl part number 0000 400 4005). Stop Switch Wire: Part number 1120 400 0800. Ensure proper air gap between flywheel and coil legs (0.3mm / 0.012").

Turn off saw and disconnect spark plug before testing.
Check for spark by grounding plug against cylinder.
Resistance values for coil: Primary ~X ohms, Secondary ~X kOhms (refer to service manual).

Tip: A weak or no spark is often caused by a faulty coil, damaged wire, or incorrect air gap.

Cutting Attachment & Guide Bar

Supports various Stihl guide bars and chains.

Clutch: Part number 1120 160 0601. Centrifugal type. Remove with special clutch tool.
Sprocket (Rim Type): Part number 1120 160 0702 for .325" pitch. Includes bearing (1120 160 0800).
Oil Pump: Part number 1120 160 0900. Adjustable via screw on bottom of saw.
Guide Bar: Stihl Rollomatic E (e.g., 3003 000 4316 for 16"). Match pitch and gauge to chain.
Chain: Stihl Oilomatic chain (e.g., 63PMX-XX for .325" .063" 16" bar). Number of drive links varies.
Chain Tensioner: Includes screw, pin, and adjuster (part numbers 1120 160 1000, 1101, 1102).
Bar Mounting Hardware: Nuts (1120 160 1200) and studs (1120 160 1300).

WARNING! Always use a sharp chain with correct tension. A loose or damaged chain can derail and cause injury.

Chassis & Handle Assembly

Anti-Vibration Springs: Part numbers 1120 790 0600 (front) and 1120 790 0700 (rear). Handle (Rear): Part number 1120 790 0801. Includes throttle trigger, lockout, and wiring. Handle (Front): Part number 1120 790 0900. Chain Brake Assembly: Part number 1120 790 1001 (if equipped). Includes band, lever, and spring. Throttle Control Linkage: Rod and springs (part numbers 1120 790 1100, 1200).

Part Numbers & Ordering Guide

Always order parts using the correct Stihl part number. Provide your saw's serial number to your dealer for accurate identification. Common wear items include: Air Filter (1120 140 0800), Spark Plug, Fuel Filter, Chain, Sprocket, Guide Bar, and Carburetor Kit.

CAUTION! Non-genuine parts may not meet specifications, potentially causing poor performance, excessive wear, or safety hazards.

Exploded View Diagrams

Refer to official Stihl IPL (Illustrated Parts List) for detailed exploded views of each assembly. Diagrams show part relationships, quantities, and part numbers. Key diagrams include: Engine Crankcase, Cylinder & Piston, Fuel System, Ignition, Clutch & Sprocket, Starter, and Complete Handle/Chassis Assembly.

Maintenance & Troubleshooting

Symptom	Possible Cause	Corrective Action / Part to Check
Engine won't start	No spark, no fuel, flooded	Check spark plug & ignition coil; check fuel lines, filter, carburetor diaphragms.
Engine runs poorly/ lacks power	Clogged air filter, faulty carburetor, exhaust port blocked	Clean/replace air filter; rebuild carburetor kit; clean muffler spark arrestor.
Chain does not oil	Empty oil tank, clogged oil passages, faulty pump	Check oil tank; clean bar groove and oil holes; inspect/replace oil pump (1120 160 0900).
Excessive vibration	Worn AV springs, unbalanced clutch, loose components	Inspect and replace AV springs (1120 790 0600/0700); check clutch and mounting nuts.
Chain brake not engaging	Worn brake band, broken spring, dirty mechanism	Inspect brake band (part of 1120 790 1001) and spring; clean and lubricate pivot points.

Regular Maintenance: Daily: Clean air filter, check chain tension. Weekly: Clean saw, check all fasteners. Seasonal: Replace fuel filter, inspect spark plug, clean cooling fins.

Service: For technical support and genuine parts, contact an authorized Stihl servicing dealer or visit www.stihlusa.com.