Stihl 026 Repair Manual PDF

The Stihl 026 is a professional-grade chainsaw known for its reliability and power. This repair manual provides comprehensive instructions for maintenance, troubleshooting, and repair of the Stihl 026 model. It covers engine disassembly and reassembly, carburetor adjustment, ignition system service, fuel system maintenance, chain and bar care, and safety procedures. Below are key sections for specifications, maintenance schedules, troubleshooting, and step-by-step repair guides.

1. Features & Specifications 2. Safety Precautions 3. Maintenance Schedule 4. Engine Repair 5. Fuel System 6. Ignition System 7. Chain & Bar Assembly 8. Carburetor Adjustment 9. Troubleshooting Guide 10. Parts List & Diagrams 11. Warranty & Support

Features & Specifications

Key components: Engine, carburetor, ignition module, fuel tank, chain brake, bar and chain.

Feature	Description
Engine Type	2-stroke, single cylinder, air-cooled
Displacement	49.4 cc (3.01 cu in)
Power Output	2.6 kW (3.5 hp)
Fuel Capacity	0.55 L (18.6 fl oz)
Oil Capacity	0.26 L (8.8 fl oz)
Chain Pitch	3/8" or .325"
Bar Length	16" to 20" (standard)
Weight (powerhead)	5.2 kg (11.5 lbs)
Ignition System	Electronic, capacitor discharge
Carburetor	Walbro or Zama diaphragm type

Safety Precautions

Always wear protective gear and follow safety guidelines.

Personal Protective Equipment: Wear safety glasses, gloves, hearing protection, and chainsaw chaps.
Work Area: Ensure clear, stable ground free of tripping hazards.
Fuel Safety: Refuel in well-ventilated area, away from ignition sources.
Chain Brake: Test chain brake before each use.

WARNING! Disconnect spark plug before performing any repairs to prevent accidental starting.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily: Check chain tension, sharpness, and lubrication.
Weekly: Clean air filter, inspect spark plug, check fuel lines.
Monthly: Clean cooling fins, check clutch and sprocket.
Annually: Replace fuel filter, inspect piston and cylinder.

CAUTION! Use only genuine Stihl parts and recommended lubricants.

Engine Repair

Cylinder & Piston: Inspect for scoring; replace if worn.
Crankshaft & Bearings: Check for play; replace bearings if noisy.
Muffler: Clean spark arrestor screen regularly.
Decompression Valve: Test for proper sealing.
Engine Seals: Replace if leaking (crankcase, crankshaft).
Tools Required: Torx screwdrivers, piston stop, flywheel puller, torque wrench.
Torque Specs: Cylinder bolts: 10 Nm; Flywheel nut: 40 Nm.
Compression: Minimum 120 psi for proper operation.

Fuel System

Components: Fuel tank, filter, lines, carburetor, primer bulb.

Fuel Mix: Use 50:1 gasoline to 2-stroke oil (Stihl HP Ultra recommended).

Fuel Line Replacement: Disconnect lines at tank and carburetor; install new lines with clamps. Fuel Filter: Replace annually or if clogged. Carburetor: Clean jets and diaphragms; adjust H, L, and LA screws. Primer Bulb: Test for cracks; replace if not priming.

Ignition System

Components: Spark plug, ignition module, flywheel, stop switch.

Spark Plug: Gap 0.020" (0.5 mm); replace if fouled or worn.
Ignition Module: Test with multimeter; replace if no spark.
Flywheel: Check key and keyway for damage; tighten nut to spec.
Stop Switch: Ensure wire is intact and grounding properly.

Tip: Use a spark tester to verify ignition output.

Chain & Bar Assembly

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

Bar Installation: Align adjustment pin; tighten nuts evenly.
Chain Tension: Adjust so chain snaps back when pulled from bar.
Sharpening: Use round file matching chain pitch (e.g., 5/32" for 3/8").
Lubrication: Check oiler hole and tank; use Stihl chain oil.
Sprocket: Replace if worn (spur or rim type).
Chain Brake: Test band and mechanism for proper engagement.
Guide Bar: Flip regularly for even wear; clean groove.
Drive Sprocket: Inspect for wear; replace if teeth are hooked.

WARNING! Always stop engine before adjusting chain tension.

Carburetor Adjustment

Adjust H (high speed), L (low speed), and LA (idle) screws.

Initial Settings: Turn H and L screws clockwise to lightly seated, then back out 1 turn each. Fine Tuning: Start saw; adjust L for smooth idle, H for maximum RPM (not exceeding 13,500 RPM). LA screw sets idle speed (chain should not move).

Care & Cleaning

Clean after each use. Use compressed air to remove debris from cooling fins and air filter.

CAUTION! Do not use high-pressure water; avoid solvents on plastic parts.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel issue, flooded	Check spark plug, fuel lines, carburetor; clear flood.
Engine runs poorly	Clogged filter, bad fuel, air leak	Clean/replace air filter; use fresh fuel; pressure test crankcase.
Chain won't turn	Clutch worn, sprocket damaged	Inspect clutch springs and shoes; replace sprocket.
Excessive vibration	Loose parts, unbalanced flywheel	Tighten all fasteners; check flywheel and clutch.
Oil not lubricating	Clogged oiler, wrong oil	Clean oil passages; use recommended chain oil.

Reset: After repairs, reset carburetor to factory settings.

Service: For technical support, contact Stihl at 1-800-467-8445 or visit www.stihlusa.com.