Stihl 044 Service Manual PDF

The Stihl 044 is a professional-grade chainsaw known for its power, durability, and reliability. This service manual provides comprehensive information for maintenance, troubleshooting, and repair of the Stihl 044 chainsaw. It covers engine specifications, fuel system, ignition system, clutch and sprocket, guide bar and chain, carburetor adjustment, and safety procedures. Below are key sections for specifications, maintenance schedules, troubleshooting, and repair procedures.

1. Specifications & Technical Data 2. Safety Information 3. Maintenance Schedule 4. Engine Service 5. Fuel System 6. Ignition System 7. Clutch & Drive System 8. Guide Bar & Chain 9. Carburetor Adjustment 10. Troubleshooting Guide 11. Exploded Views & Parts List

Specifications & Technical Data

Key technical specifications for the Stihl 044 chainsaw.

FeatureSpecification
Engine Displacement70.7 cc (4.3 cu. in.)
Power Output4.4 kW (6.0 HP)
Fuel Tank Capacity0.75 L (25.4 fl. oz.)
Oil Tank Capacity0.33 L (11.2 fl. oz.)
Weight (Powerhead)6.2 kg (13.7 lbs)
Guide Bar Length (Recommended)40 cm (16") to 63 cm (25")
Chain Pitch3/8" or .325"
Ignition SystemElectronic, capacitor discharge (CDI)
CarburetorWalbro or Zama diaphragm type
Spark PlugBosch WSR6F or equivalent

Safety Information

Essential safety precautions before operating or servicing the chainsaw.

  1. Personal Protective Equipment (PPE): Always wear safety glasses, hearing protection, gloves, chainsaw chaps, and steel-toed boots.
  2. Work Area Safety: Ensure a clear work area, secure footing, and no bystanders within 15 feet.
  3. Chain Brake: Test the chain brake functionality before each use.
  4. Fuel Safety: Refuel in a well-ventilated area with the engine off and cool. Use fresh, clean fuel mix.
  5. Kickback Zone: Avoid contact with the upper quadrant of the guide bar tip.

WARNING! Failure to follow safety procedures can result in serious injury or death. Disconnect the spark plug wire before performing any service.

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

  1. Before Each Use: Check chain tension, sharpness, and lubrication. Inspect for loose fasteners and damage.
  2. Every 10 Hours: Clean air filter, check spark plug condition, clean cooling fins, inspect fuel filter.
  3. Every 20 Hours: Clean spark arrestor screen (if equipped), check clutch and sprocket for wear.
  4. Every 50 Hours: Replace fuel filter, clean carburetor (external), check anti-vibration elements.
  5. Every 100 Hours: Replace spark plug, clean muffler, check piston and cylinder through exhaust port.
  6. Annually or 300 Hours: Replace air filter, fuel lines, and impulse line. Professional engine inspection recommended.

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

Engine Service

Fuel System

Components include fuel tank, lines, filter, and carburetor.

Fuel Lines: Inspect for cracks, stiffness, or leaks. Replace every 2 years or as needed.

Fuel Filter: Located in fuel tank. Replace when clogged or annually.

Carburetor: Walbro HD or Zama C1M series. Includes adjustment screws for idle (L), high speed (H), and idle speed (LA).

Fuel Mix: Use high-quality 2-stroke engine oil mixed with unleaded gasoline at a 50:1 ratio (2% oil).

Ignition System

Electronic ignition module (CDI), spark plug, and stop switch.

  1. Check spark plug gap: 0.5 mm (0.020 in).
  2. Test for spark: Remove plug, ground it against cylinder, pull starter. Strong blue spark indicates good ignition.
  3. Ignition Module: Resistance testing per manual specifications. Replace if no spark and wiring is intact.
  4. Stop Switch: Ensure wire is not grounded or damaged, preventing engine start.

Tip: A weak or no spark is often due to a faulty ignition module, damaged wire, or bad spark plug.

Clutch & Drive System

Centrifugal clutch, drum, and drive sprocket.

  1. Clutch Inspection: Remove cover and clutch assembly. Check shoes for wear, cracking, or glazing.
  2. Clutch Spring: Ensure springs are intact and provide tension.
  3. Drive Sprocket: Check for wear (hook-shaped teeth). Replace if worn to prevent chain damage.
  4. Needle Bearing: Lubricate with high-temperature grease during reassembly.
  5. Clutch Drum: Inspect for grooves from chain contact. Replace if deeply scored.

WARNING! The clutch engages at high RPM. Ensure the chain brake is engaged and spark plug disconnected during service.

Guide Bar & Chain

Proper maintenance ensures cutting efficiency and safety.

Guide Bar: Regularly clean oil channels and groove. Dress bar rails with a flat file to remove burrs. Rotate bar weekly for even wear.

Chain Sharpening: Use correct round file size (typically 5.5 mm for 3/8" chain). Maintain correct filing angle (30°). Ensure depth gauges are properly set.

Chain Tension: Adjust so chain snaps back when pulled from bar. It should not sag from the bar rail.

Lubrication: Always use bar and chain oil. Check oiler output and adjust if necessary.

Carburetor Adjustment

Standard initial settings for Walbro carburetor: L screw - 1 turn open, H screw - 1 turn open, LA screw - 1 turn open.

  1. Final Adjustment (Warm Engine):
    • Turn L screw for fastest idle, then 1/4 turn back.
    • Turn H screw for maximum RPM (do not exceed 13,500 RPM no-load).
    • Set idle speed (LA) so chain does not move and engine runs smoothly.
  2. Use a tachometer for precise H screw adjustment.
  3. Ensure engine accelerates smoothly from idle to full throttle without hesitation.

CAUTION! Over-leaning the H screw can cause engine seizure. Rich is safer than lean.

Troubleshooting Guide

SymptomPossible CauseCorrective Action
Engine will not startNo spark, flooded, fuel issueCheck spark, plug condition. Dry plug if flooded. Check fuel lines, filter, and carburetor.
Engine starts then diesClogged fuel filter, carburetor adjustment, air leakReplace fuel filter. Adjust carburetor. Check crankcase seals and intake boot for leaks.
Loss of powerClogged air filter, muffler, carburetor, compression lossClean/replace air filter and muffler. Service carburetor. Check compression (should be >120 psi).
Chain does not turnClutch worn, sprocket worn, brake engagedInspect clutch and sprocket. Disengage chain brake.
Excessive vibrationLoose components, unbalanced chain, damaged AV mountsTighten all fasteners. Balance chain. Replace anti-vibration buffers.
Oil not dispensingClogged oiler holes, worn pump, empty tankClean bar oil channels. Inspect oil pump gear and worm drive. Fill oil tank.

Compression Test: Reading below 100 psi indicates worn piston rings, cylinder, or leaking gasket.

Service: For complex repairs, consult an authorized Stihl servicing dealer.

Exploded Views & Parts List

Refer to the official Stihl 044 parts manual (PDF) for detailed exploded diagrams and part numbers for every assembly, including:

Always use the correct Stihl part number when ordering replacements.

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