Stihl 036 Service Manual

The Stihl 036 is a professional-grade chainsaw featuring a high-performance engine, electronic ignition, anti-vibration system, and advanced safety features. This service manual provides comprehensive instructions for maintenance, troubleshooting, repair, and safety procedures. Below are key sections covering specifications, safety, maintenance schedules, engine service, fuel system, ignition system, cutting equipment, and troubleshooting.

Specifications & Technical Data

Key technical specifications for the Stihl 036 chainsaw.

Feature	Specification
Engine Type	2-stroke, single cylinder, air-cooled
Displacement	61.5 cc (3.75 cu. in.)
Power Output	3.6 kW (4.8 hp)
Fuel Tank Capacity	550 ml (18.6 fl. oz.)
Oil Tank Capacity	260 ml (8.8 fl. oz.)
Guide Bar Length (Max)	50 cm (20 inches)
Chain Pitch	3/8" or .325"
Weight (Powerhead)	6.2 kg (13.7 lbs)
Ignition System	Electronic, CDI
Spark Plug	Bosch WSR6F or equivalent

Safety Instructions & Warnings

Critical safety procedures to prevent injury and damage.

1. Always wear appropriate PPE: safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.
2. Ensure the chain brake is functional before each use.
3. Never operate the saw with a loose, damaged, or improperly tensioned chain.
4. Use the correct fuel/oil mixture (50:1 with Stihl HP Ultra or equivalent).
5. Work in a well-ventilated area when refueling.

WARNING! A chainsaw is a dangerous tool. Failure to follow safety instructions can result in serious injury or death. Always disconnect the spark plug before performing any maintenance.

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

1. Daily/Before Use: Check chain tension, sharpness, and lubrication. Inspect for loose fasteners and damage.
2. Weekly/Every 10 Hours: Clean air filter, check spark plug condition, clean cooling fins and external surfaces.
3. Monthly/Every 50 Hours: Clean fuel filter, check fuel lines, clean spark arrestor screen (if equipped).
4. Annually/Every 100 Hours: Replace fuel filter, inspect clutch and sprocket, check anti-vibration elements.

CAUTION! Use only genuine Stihl parts or approved equivalents to maintain performance and safety.

Engine Service & Overhaul

• Cylinder & Piston: Inspection for scoring, carbon buildup, and ring wear.
• Crankcase & Crankshaft: Checking seals, bearings, and connecting rod play.
• Decompression Valve: Testing and replacement procedure.
• Muffler: Removal, cleaning of carbon deposits, and spark arrestor service.
• Compression Test: Procedure and acceptable pressure range (120-150 psi).
• Rebuild Kits: Part numbers for piston/cylinder assemblies and gasket sets.

Fuel System & Carburetor

Service procedures for the Walbro or Zama carburetor and associated components.

Components: Fuel tank, fuel lines, fuel filter, carburetor, primer bulb, and throttle linkage.

Carburetor Adjustment: Idle speed (L), Low-speed mixture (LA), High-speed mixture (H). Standard initial settings: L = 1 turn out, H = 1 turn out. Fine-tune for smooth acceleration and maximum RPM under load (13,500 - 14,500 RPM).

Fuel Line Replacement: Steps for removing and installing new fuel lines and filter.

Ignition System & Electrical

Testing and servicing the electronic ignition module, spark plug, and stop switch.

1. Disconnect spark plug wire before testing.
2. Check spark plug gap (0.020" or 0.5 mm).
3. Test ignition coil resistance values (primary: 0.1-0.5 Ω, secondary: 5-15 kΩ).
4. Inspect flywheel key for shearing and flywheel for damage.
5. Verify operation of the stop switch and wiring harness.

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

Cutting Equipment & Bar/Chain

Maintenance for guide bar, saw chain, and drive sprocket.

1. Bar Maintenance: Clean bar groove, flip bar regularly for even wear, check for straightness and burrs.
2. Chain Sharpening: Use correct round file size (typically 4.0 mm or 5/32"), maintain correct filing angle (30°).
3. Chain Tension: Proper adjustment - snug against bar but pullable by hand.
4. Sprocket Inspection: Check for wear (replace if teeth are hooked).
5. Oil System: Test oil flow, clean oil ports, adjust oil pump output if applicable.

WARNING! A dull or improperly tensioned chain increases kickback risk and operator fatigue. Always stop the engine before adjusting the chain.

Clutch & Drive System

Service procedures for the centrifugal clutch, drum, and bearing.

Clutch Removal: Steps to remove clutch assembly using a clutch holding tool and appropriate socket.

Inspection: Check clutch shoes for wear, springs for integrity, and drum for scoring.

Bearing Replacement: Procedure for replacing the needle bearing in the clutch drum.

Anti-Vibration System

Inspection and replacement of AV springs and buffers.

Locate and inspect the four main AV elements connecting the engine to the rear handle and fuel tank housing. Replace if cracked, hardened, or deformed.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine will not start	No spark, flooded, fuel issue	Check spark, dry plug, verify fuel flow and mixture.
Engine starts then dies	Clogged fuel filter, carb adjustment	Replace fuel filter, clean carburetor, adjust L screw.
Loss of power under load	Clogged air filter, muffler, carb H setting	Clean/replace air filter, clean spark arrestor, adjust H screw.
Excessive vibration	Loose components, damaged AV mounts, unbalanced clutch	Tighten fasteners, replace AV elements, inspect clutch.
Chain does not oil	Empty oil tank, clogged oil passages, faulty pump	Fill tank, clean bar groove and oil ports, inspect/replace pump.
Chain rotates at idle	Idle RPM too high, worn clutch springs	Adjust idle speed screw (LA), replace clutch springs.

Reset: After major repairs, retune carburetor and perform a functional test.

Parts Diagrams & Ordering

Reference exploded-view diagrams for assembly and part identification. Use genuine Stihl part numbers when ordering replacements. For support, contact an authorized Stihl servicing dealer or visit www.stihlusa.com.

Common Part Numbers (Example):
Air Filter: 0000 120 1620
Fuel Filter: 0000 350 3501
Spark Plug: BOSCH WSR6F
Clutch Assembly: 1123 160 2001
AV Buffer Set: 1128 790 0800