stihl 024 chainsaw manual pdf

The STIHL 024 is a professional-grade gasoline chainsaw designed for demanding forestry, landscaping, and cutting tasks. It features a robust engine, anti-vibration system, quick-stop chain brake, and STIHL's Ematic lubrication system. This manual covers essential safety procedures, technical specifications, daily operation, maintenance schedules, troubleshooting, and parts identification for the STIHL 024 chainsaw.

1. Safety Instructions & Symbols 2. Specifications & Components 3. Assembly & First-Time Setup 4. Fuel & Lubricants 5. Starting & Stopping Procedures 6. Operating Instructions 7. Maintenance Schedule 8. Chain & Guide Bar Care 9. Troubleshooting Guide 10. Parts Diagram & List 11. Warranty & Service

Safety Instructions & Symbols

Critical safety information to prevent serious injury or death. Understand all warning symbols and instructions before operation.

Symbol/Area	Description
⚠️ General Warning	Indicates a potentially hazardous situation.
🔥 Fire Hazard	Keep away from sparks, open flames, and heat sources when refueling.
👂 Hearing Protection	Prolonged exposure to noise can cause hearing loss. Always wear approved hearing protection.
🛡️ Protective Equipment	Mandatory use of safety helmet, eye protection, gloves, chainsaw chaps, and sturdy boots.
⚡ Kickback Zone	Do not cut with the upper quadrant of the guide bar tip to avoid kickback.
🛑 Chain Brake	Test the chain brake functionality before each use.

Specifications & Components

Key technical data and major components of the STIHL 024 chainsaw.

Engine Displacement: 40.2 cc (2.45 cu. in.)
Power Output: 2.0 kW (2.7 bhp)
Fuel Tank Volume: 0.55 L (18.6 fl. oz.)
Oil Tank Volume: 0.26 L (8.8 fl. oz.)
Guide Bar Lengths: 40 cm (16") to 50 cm (20") recommended.
Chain Pitch/Gauge: 3/8" P / .050" (1.3 mm) typically.
Weight (powerhead): Approximately 5.2 kg (11.5 lbs).
Ignition System: STIHL Electronic Ignition (CDI).
Anti-Vibration System: Standard.
Lubrication System: STIHL Ematic with adjustable oil pump.

Assembly & First-Time Setup

Steps to prepare your new STIHL 024 chainsaw for operation.

Attach Guide Bar & Chain: Place bar on studs, fit chain with drive links in bar groove and cutting edges facing forward on top. Install clutch cover and tighten nuts evenly.
Fill Chain Oil: Use STIHL HP or equivalent bar and chain oil. Fill to tank mark.
Mix Fuel: Use 50:1 mixture of unleaded gasoline (min. 89 octane) and STIHL 2-cycle engine oil. Shake well.
Adjust Chain Tension: Loosen nuts, use adjustment screw to raise bar tip until chain fits snugly against bar. Retighten nuts securely.

WARNING! Never operate the saw without proper chain tension and lubrication. Failure can cause chain derailment, breakage, or excessive wear.

Fuel & Lubricants

Correct fluids are essential for performance and engine life.

Fluid	Specification	Purpose
Fuel Mix	50:1 Gasoline to STIHL 2-Cycle Oil	Engine combustion and lubrication.
Bar & Chain Oil	STIHL HP or ISO VG 100 equivalent	Lubricates chain and guide bar to reduce friction and wear.
Gear Housing Grease	STIHL Multi-Purpose Grease	Lubricates spur gear (if equipped).

CAUTION! Do not use automotive motor oil, dirty fuel, or fuel older than 30 days. Store fuel in an approved container.

Starting & Stopping Procedures

Cold Start (Engine not warm):

Set master control lever to choke position (⬇).
Press decompression valve (if equipped).
Pump primer bulb 5-7 times until fuel is visible.
Place saw on firm ground, hold front handle with left hand, place right foot in rear handle.
Pull starter rope sharply until engine fires (usually 3-5 pulls).
Immediately move master control lever to half-throttle position (⬆).
Pull starter rope again to start. Allow to idle briefly before applying throttle.

Stopping: Release throttle, allow engine to idle, then move master control lever to STOP (0) position.

Operating Instructions

Proper cutting techniques for safety and efficiency.

Pre-Cut Check: Verify chain brake is off, chain is sharp and tensioned, area is clear.
Basic Stance: Stand with feet shoulder-width apart, left foot slightly forward. Hold saw firmly with both hands.
Making the Cut: Use full throttle before contacting wood. Let the saw do the work; do not force it. Beware of pinch points.
Kickback Prevention: Maintain a firm grip, do not cut above shoulder height, never use the tip of the bar.
Refueling: Stop engine and allow to cool for several minutes. Clean area around fuel cap. Refill in a well-ventilated area.

Tip: Plan an escape path free of tripping hazards before felling any tree.

Maintenance Schedule

Regular maintenance ensures longevity and safe operation.

Interval	Task
Before Each Use	Check chain tension, sharpness, and lubrication. Inspect for loose fasteners or damage.
Every 5 Hours	Clean air filter (more often in dusty conditions). Check spark plug condition.
Every 20 Hours	Clean spark arrestor screen (if equipped). Clean cooling fins. Check fuel filter.
Every 100 Hours	Replace fuel filter. Clean carburetor air passage. Check anti-vibration elements.
Annually	Have saw inspected by an authorized STIHL servicing dealer.

Chain & Guide Bar Care

Proper care of the cutting system is critical.

Sharpening: Use correct round file size (typically 4.0mm or 5/32"). Maintain original filing angles (usually 30°). File all cutters to equal length.
Depth Gauge Setting: Use a flat file and depth gauge tool to maintain proper clearance (approx. 0.025" / 0.65mm below cutting edge).
Guide Bar Maintenance: Regularly clean bar groove. Flip bar weekly for even wear. Dress bar rails with a flat file if burred.
Lubrication Check: Run saw at full throttle pointed at a light-colored surface (e.g., stump). A fine line of oil should be visible.

WARNING! A dull or improperly sharpened chain increases the risk of kickback and operator fatigue.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, old fuel, clogged filter	Check spark plug; use fresh fuel mix; clean/replace air & fuel filters; move control to half-throttle if flooded.
Engine starts but dies	Clogged fuel filter, carburetor issues, vent blocked	Replace fuel filter; clean fuel tank vent; may require carburetor adjustment by dealer.
Loss of power	Dirty air filter, clogged spark arrestor, dull chain	Clean air filter and spark arrestor screen; sharpen chain.
Chain does not turn	Clutch worn, drive sprocket worn, chain brake engaged	Disengage chain brake; inspect clutch and sprocket for wear; replace if necessary.
Excessive vibration	Loose components, damaged anti-vibration mounts, unbalanced chain	Tighten all fasteners; check anti-vibration elements; ensure chain is properly sharpened.
Chain throws oil excessively	Oil pump output set too high	Adjust oil pump screw (usually located near oil tank) counter-clockwise to reduce flow.

Parts Diagram & List

Reference diagram for identifying key replacement parts (Diagram would be inserted here in actual manual).

1110 141 2001: Cylinder Assembly
1110 140 2001: Piston Assembly
1110 400 0801: Carburetor (Zama C1Q-S267)
1110 007 1003: Ignition Module
1110 350 2600: Starter Assembly
1110 790 4801: Guide Bar, 16" (3005 000 4801)
1125 007 1057: Saw Chain, 16" (63 Drive Links)
1110 007 1800: Air Filter
1110 141 0905: Fuel Filter
1110 007 1060: Spark Plug (Bosch WSR6F or equivalent)

Note: Always use genuine STIHL replacement parts to ensure performance and safety.

Warranty & Service

STIHL Limited Warranty: Contact your authorized STIHL dealer for warranty terms and duration in your region.

Service: Repairs and adjustments requiring special tools or knowledge (e.g., carburetor adjustment, engine disassembly) must be performed by an authorized STIHL servicing dealer.

For the location of your nearest STIHL dealer, visit www.stihlusa.com or call 1-800-467-8445.

Disposal: At end of life, do not dispose with household waste. Take to an authorized STIHL dealer or recycling center for proper disposal of fluids and components.