Stihl 038 AV Manual

The Stihl 038 AV is a professional-grade gasoline chainsaw featuring anti-vibration (AV) technology, a powerful engine, and durable construction for demanding forestry and cutting applications. This manual covers safety instructions, technical specifications, assembly, operation, maintenance, troubleshooting, and parts identification. Always read and understand this manual before operating the saw.

Safety Instructions

Operating a chainsaw involves serious risks. Follow all safety rules to prevent severe injury or death.

Hazard	Precaution
Kickback	Always hold saw firmly with both hands; use reduced-kickback chain; do not saw with tip.
Cutting hazards	Wear protective gear: helmet, goggles, ear protection, gloves, chainsaw chaps, and boots.
Fuel handling	Refuel only when engine is cool, outdoors, and away from ignition sources.
Electrical lines	Check work area for hidden power lines before cutting.
Fatigue	Take regular breaks; fatigue leads to loss of control.
Work area	Keep bystanders and pets at least 20 feet away.
Chain brake	Test chain brake function before each use.
Transport	Engage chain brake and fit scabbard when carrying.
Maintenance	Disconnect spark plug before performing maintenance.
Starting	Place saw on ground, secure with foot, and pull starter cord firmly.

WARNING! Failure to follow safety instructions can result in serious injury or death. This saw is for trained users only.

Features & Components

Key components and their functions for the Stihl 038 AV.

1. Anti-Vibration System (AV): Reduces operator fatigue by dampening engine vibrations.
2. Engine: Two-stroke, single-cylinder gasoline engine with electronic ignition.
3. Chain Brake: Inertia-activated safety feature to stop chain in kickback events.
4. Throttle Trigger & Lockout: Prevents accidental throttle engagement.
5. Master Control Lever: Combines choke, throttle setting, and stop switch functions.
6. Decompression Valve: Eases starting by reducing cylinder pressure.
7. Chain Tensioner: Side-mounted for easy chain adjustment without tools.
8. Fuel & Oil Caps: Clearly marked for fuel mix and bar/chain oil.
9. Spark Arrestor Muffler: Reduces exhaust sparks and noise.
10. Handle: Ergonomic rear handle and wraparound front handle with vibration dampeners.

Technical Specifications

• Model: Stihl 038 AV
• Engine Displacement: 61.5 cc (3.75 cu. in.)
• Power Output: 3.6 kW (4.8 hp)
• Fuel Tank Capacity: 0.75 L (25.4 fl. oz.)
• Oil Tank Capacity: 0.32 L (10.8 fl. oz.)
• Recommended Bar Lengths: 16" to 24" (40 cm to 60 cm)
• Chain Pitch/Gauge: 3/8" P / .063" (1.6 mm) or .050" (1.3 mm)
• Weight (Powerhead): 6.6 kg (14.6 lbs) without bar and chain
• Ignition System: Electronic, breakerless
• Idle Speed: 2,800 rpm
• Maximum Power Speed: 9,500 rpm
• Sound Pressure Level: 106 dB(A)
• Vibration Level (Front/Rear Handle): 4.5 / 2.5 m/s²

Assembly & Preparation

Assembling your new Stihl 038 AV chainsaw.

1. Unpacking: Remove all packaging material. Check contents against packing list.
2. Attaching Guide Bar & Chain: Place bar on studs. Loop chain over sprocket, ensuring cutting teeth face forward on top of bar. Fit chain tensioning pin into bar hole. Install bar nuts finger-tight.
3. Tensioning Chain: Lift bar tip. Using combination tool, turn tensioning screw clockwise until chain fits snugly against bar but can be pulled around by hand. Tighten bar nuts securely.
4. Filling Fluids: Fill fuel tank with proper gasoline/oil mixture (see Section 5). Fill oil tank with STIHL chain oil or equivalent.
5. Final Check: Ensure all fasteners are tight. Check chain brake function by pushing front hand guard forward—it should snap into braking position.

CAUTION! Never operate the saw without proper chain tension and lubrication.

Fuel & Lubrication

Proper fuel and oil are critical for performance and engine life.

Fuel Mixture:

• Use unleaded gasoline with a minimum octane rating of 89 (RON).
• Mix with high-quality two-stroke engine oil at a ratio of 50:1 (2% oil).
• Use STIHL HP Ultra or an ISO-L-EGD/ JASO FD certified oil.
• Shake fuel can thoroughly before refueling.
• Never use straight gasoline or motor oil.

Bar & Chain Oil:

• Use STIHL chain oil or a biodegradable chainsaw oil with good adhesive properties.
• In cold weather (below 41°F / 5°C), use winter-grade chain oil.
• Check oil flow before cutting: Hold saw over light-colored surface and run at full throttle—a line of oil should appear on the surface.

Starting & Operation

Starting procedure for cold and warm engines.

1. Cold Start:
   • Engage chain brake by pushing hand guard forward.
   • Set Master Control Lever to choke position (full down).
   • 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 through rear handle.
   • Pull starter cord briskly until engine 'fires' (usually 3-5 pulls).
   • Move Master Control Lever to half-throttle position (mid-notch).
   • Pull starter cord again until engine starts.
   • Briefly blip throttle to disengage choke. Allow to warm up 30 seconds.
2. Warm Start: Set Master Control Lever to half-throttle position and pull starter cord.
3. Operation:
   • Disengage chain brake by pulling hand guard toward you.
   • Use full throttle when cutting. Do not 'lug' the engine.
   • Let chain do the work—avoid excessive pressure.
   • For felling, follow established techniques and use wedges.
4. Stopping: Release throttle, allow engine to idle, then move Master Control Lever to STOP position.

Maintenance Schedule

Interval	Task	Details
Daily	Clean air filter	Remove, tap clean, or wash with soapy water if foam. Dry completely before reinstalling.
Daily	Check chain tension	Adjust when chain sags from bar rails. Chain should be snug but pull freely.
Daily	Clean saw body & cooling fins	Remove sawdust with brush. Ensure muffler screen is clear.
Every 10 hours	Check spark plug	Clean electrode, adjust gap to 0.020" (0.5 mm). Replace if worn.
Every 20 hours	Clean fuel filter	Replace if clogged. Located inside fuel tank.
Every 50 hours	Clean spark arrestor screen	Remove muffler cover, clean screen with wire brush.
Annually	Check clutch & sprocket	Replace if worn. Inspect anti-vibration mounts.
As needed	Sharpen chain	Use round file and guide. Maintain correct filing angle (typically 30°).

Chain & Bar Care

Proper care extends the life of your cutting equipment.

1. Sharpening: Use correct file diameter for your chain (usually 5/32" or 3/16"). File each cutter at the specified angle (check chain marking). File all cutters to equal length. File depth gauges (rakers) with a flat file and gauge.
2. Bar Maintenance: Regularly clean bar groove with a bar groove cleaner. Flip bar weekly to ensure even wear. Dress bar rails with a flat file if burred.
3. Chain Replacement: Replace chain when cutters are worn down to the wear line, or if damaged. Always match pitch, gauge, and drive link count.
4. Storage: Coat bar and chain with oil to prevent rust during storage.

Tip: A sharp chain cuts faster, reduces operator fatigue, and is safer than a dull one.

Troubleshooting

Problem	Possible Cause	Solution
Engine will not start	No spark; flooded; stale fuel; clogged filter	Check spark plug; wait if flooded; use fresh fuel mix; clean air/fuel filters.
Engine starts then dies	Clogged fuel tank vent; dirty carburetor	Clean vent hole in fuel cap; have carburetor serviced.
Loss of power	Dirty air filter; clogged spark arrestor; poor fuel	Clean air filter & muffler screen; use fresh fuel mix.
Chain does not turn	Chain brake engaged; clutch worn; sprocket damaged	Disengage brake; inspect clutch drum and sprocket.
Excessive vibration	Loose fasteners; worn AV mounts; unbalanced chain	Tighten all nuts/bolts; replace AV buffers; sharpen chain evenly.
Chain throws oil but doesn't cut	Dull chain; incorrect filing angle	Sharpen chain properly; check depth gauge height.
Chain comes off bar	Loose chain; worn bar; damaged drive links	Tension chain properly; replace bar if groove widened; inspect chain.
Oil not flowing to bar	Empty oil tank; clogged oil passages; faulty pump	Fill tank; clean oil ports; check oil pump drive.

Parts Diagram

Refer to the official Stihl 038 AV Parts Manual (PN 0000 950 4303) for exploded views and part numbers. Key assemblies include:

• Cylinder & Piston Group
• Crankcase & Crankshaft
• Carburetor & Air Filter System
• Ignition System (Flywheel, Coil, Switch)
• Clutch, Sprocket & Chain Brake
• Fuel & Oil Tanks with Pumps
• Anti-Vibration Handle System
• Guide Bar & Chain
• Starter Assembly
• Muffler & Heat Shields

Note: Use only genuine STIHL replacement parts to ensure safety and performance.

Warranty & Support

Warranty: STIHL Limited Warranty. Duration varies by region. Proof of purchase required. Warranty does not cover damage from misuse, improper fuel, neglect, or unauthorized repairs.

Service: Repairs should be performed by an authorized STIHL servicing dealer.

Support:

• Find a dealer: Visit www.stihlusa.com (USA) or your national STIHL website.
• Customer Service: Contact your local STIHL subsidiary.
• Manual Updates: Check website for latest documentation.

Disposal: At end of life, dispose of the chainsaw in accordance with local environmental regulations. Do not dispose with household waste.