Stihl 032 AV Repair Manual

The Stihl 032 AV is a professional-grade chainsaw featuring anti-vibration technology, renowned for its durability and power in demanding cutting applications. This repair manual provides comprehensive instructions for maintenance, troubleshooting, disassembly, and reassembly of the saw. Below are key sections covering safety, specifications, maintenance procedures, engine repair, fuel system, ignition system, and troubleshooting.

Features at a Glance

Key components: Anti-vibration (AV) system, single-cylinder two-stroke engine, manual oiler, chain brake, decompression valve, and electronic ignition.

Feature	Description
Anti-Vibration System	Reduces operator fatigue by dampening engine vibrations
Engine Displacement	54.1 cc (3.3 cu. in.) two-stroke
Power Output	3.0 kW (4.0 hp) at 8000 RPM
Fuel Tank Capacity	0.55 liters (18.6 fl. oz.)
Oil Tank Capacity	0.26 liters (8.8 fl. oz.)
Chain Pitch	3/8" or .325" (depending on model variant)
Ignition System	Electronic, breakerless
Starting System	Manual recoil with decompression valve
Weight (without bar & chain)	Approx. 6.2 kg (13.7 lbs)
Bar Length Range	40 cm (16") to 50 cm (20")

Safety Precautions

Always prioritize safety when operating or repairing the chainsaw.

1. Wear Personal Protective Equipment (PPE): Safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.
2. Work in a well-ventilated area away from sparks or open flames when handling fuel.
3. Disconnect the spark plug wire before performing any repair to prevent accidental starting.
4. Use only Stihl-approved replacement parts and lubricants.
5. Secure the saw properly before disassembly.

WARNING! Fuel is highly flammable. Do not smoke. Allow engine to cool before refueling or servicing.

Specifications

• Model: Stihl 032 AV
• Engine Type: Single-cylinder, two-stroke, air-cooled
• Bore x Stroke: 46 mm x 32 mm
• Compression Ratio: 7.5:1
• Idle Speed: 2800 RPM
• Maximum Power Speed: 8000 RPM
• Fuel Mix Ratio: 50:1 (Gasoline to Stihl HP Ultra or equivalent 2-stroke oil)
• Spark Plug: Bosch WSR6F or equivalent, gap 0.5 mm (0.020")
• Ignition Air Gap: 0.3 mm (0.012")
• Carburetor: Tillotson HS or Zama C1 series

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily/Before Use: Check chain tension and sharpness, inspect bar for wear, check fuel and oil levels, ensure all fasteners are tight.

Every 10 Operating Hours: Clean air filter, check spark plug condition, clean cooling fins and external surfaces.

Every 20 Operating Hours: Clean spark arrestor screen (if equipped), inspect fuel filter, check anti-vibration elements.

Every 50 Operating Hours: Clean carburetor, replace fuel filter, check clutch and sprocket.

Annually or Every 100 Hours: Replace spark plug, inspect piston through exhaust port, check all gaskets and seals.

Engine Disassembly & Reassembly

Major engine work requires careful step-by-step procedures.

1. Remove top cover, air filter, and carburetor.
2. Remove muffler and spark plug.
3. Remove clutch assembly using clutch removal tool (Stihl 0000 893 4300).
4. Separate engine housing halves by removing all screws. Note their locations.
5. Remove cylinder and piston assembly. Inspect for scoring, ring wear, and carbon buildup.
6. Remove crankshaft and bearings from crankcase if necessary.
7. Reassembly: Reverse order, using new gaskets and seals. Torque cylinder bolts to 10 Nm (7.4 ft-lb). Ensure piston ring gaps are aligned with locating pins.

Tip: Take photos during disassembly for reference. Keep small parts organized.

Fuel System Repair

Common issues include clogged filters, faulty fuel lines, and carburetor problems.

1. Drain fuel tank completely.
2. Remove fuel tank and inspect fuel lines for cracks or brittleness. Replace if necessary.
3. Replace in-tank fuel filter. Use Stihl part number 0000 350 3501.
4. Clean carburetor: Disassemble, soak jets in carburetor cleaner, blow out passages with compressed air. Replace diaphragm and gaskets (repair kit recommended).
5. Reinstall, ensuring all connections are airtight.

CAUTION! Use only ethanol-free fuel or fuel with less than 10% ethanol to prevent carburetor damage.

Ignition System

Electronic ignition module testing and replacement.

1. Check spark: Remove spark plug, reconnect wire, ground plug against cylinder, pull starter. Look for strong blue spark.
2. No spark? Check spark plug wire for damage. Test ignition coil resistance (primary: ~0.5-1.5 Ω, secondary: ~5-15 kΩ). Values outside range indicate a faulty coil.
3. Check stop switch wire for continuity to ground when off.
4. Replace ignition module (Stihl part 0000 400 1303) if faulty. Set air gap to 0.3 mm with feeler gauge.

Chain & Bar Maintenance

Proper chain care is critical for safety and performance.

1. Sharpening: Use correct round file size (typically 4.0 mm or 5/32"). Maintain 30° cutting angle and 10° top plate filing angle. File all cutters to equal length.
2. Tensioning: Chain should snap back when pulled from bar. Adjust tensioning screw with bar nuts loose. Retighten nuts after adjustment.
3. Bar Maintenance: Flip bar weekly for even wear. Clean bar groove and oil holes. Dress bar rails with a flat file if burred.
4. Sprocket: Inspect drive sprocket for wear. Replace if teeth are hooked or significantly worn.

WARNING! Always wear heavy gloves when handling the chain.

Carburetor Adjustment

Adjustment screws: L (Low speed), H (High speed), LA (Idle speed).

1. Start with factory settings: L: 1 turn open, H: 1 turn open, LA: 1 turn open.
2. Start engine and warm up for 5 minutes.
3. Adjust idle speed (LA) so chain just stops moving.
4. Adjust L screw for fastest, smoothest idle. Then readjust LA if necessary.
5. With throttle fully open, adjust H screw for maximum RPM (not exceeding 12,500 RPM no-load). A tachometer is recommended.
6. Final check: Chain must not move at idle. Engine should accelerate smoothly from idle to full throttle.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, fuel issue	Check spark, plug condition. Dry plug if flooded. Check fuel lines, filter, and carburetor.
Engine starts but dies	Clogged fuel filter, carb adjustment, air leak	Replace fuel filter. Adjust L screw. Check crankcase seals and intake manifold for leaks.
Lacks power under load	Clogged air filter, exhaust screen, carb H setting	Clean/replace air filter. Clean spark arrestor screen. Adjust H screw.
Excessive vibration	AV mounts damaged, clutch imbalance, loose parts	Inspect and replace AV buffers. Check clutch balance. Tighten all fasteners.
Chain does not oil	Empty oil tank, clogged oil passages, faulty oil pump	Fill tank. Clean bar oil holes and tank vent. Inspect/replace oil pump (part 1115 640 3201).

Reset: For electronic issues, disconnect spark plug wire for 1 minute to reset module.

Parts Diagram & List

Refer to official Stihl IPL (Illustrated Parts List) for detailed diagrams. Key replacement part numbers:

• Piston Kit: 1125 030 2003
• Cylinder: 1125 020 2001
• Crankshaft: 1125 040 2001
• Carburetor Repair Kit: 1125 007 1000
• Fuel Line: 1115 358 7700
• Ignition Module: 0000 400 1303
• AV Buffer Set: 1115 790 4800
• Clutch Assembly: 1115 160 2003

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