Stihl Wood Boss 024 AV Owner's Manual

The Stihl Wood Boss 024 AV is a professional-grade gasoline-powered chainsaw designed for demanding cutting tasks. It features the STIHL Anti-Vibration (AV) system for reduced operator fatigue, an electronic ignition system, automatic chain oiling, a decompression valve for easier starting, and a chain brake for enhanced safety. Below are key sections for safety, features, assembly, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Engine with electronic ignition, Anti-Vibration system, Chain Brake, Automatic Oiler, Decompression Valve, and Quickstop® Inertia Chain Brake.

Assembly & Preparation

Unpack and inspect all contents. Assemble on a clean, stable surface.

1. Attach the guide bar and chain: Place bar over studs, loop chain over sprocket and onto bar groove, tension correctly.
2. Fill with fuel: Use STIHL 2-stroke engine oil mixed with unleaded gasoline (50:1 ratio).
3. Fill with bar and chain oil: Use STIHL chain oil or equivalent.
4. Check chain tension: Chain should be snug against the bar but pull freely by hand.

WARNING! Always wear appropriate Personal Protective Equipment (PPE): safety glasses, hearing protection, gloves, chainsaw chaps, and sturdy boots.

First-Time Operation

Before first start, perform a safety check and familiarize yourself with controls.

1. Safety Check: Ensure chain brake is functional, chain is sharp and properly tensioned, all nuts and bolts are tight.
2. Starting Position: Place saw on firm ground, hold front handle with left hand, place right foot in rear handle.
3. Cold Start: Set master control lever to choke position, pull starter rope until engine fires, move lever to fast idle, pull to start.
4. Warm Start: Set master control lever to fast idle position and pull starter rope.

CAUTION! Never drop-start the saw. Keep bystanders at a safe distance.

Specifications

• Engine Displacement: 40.2 cc (2.46 cu. in.).
• Power Output: 2.2 kW (3.0 bhp).
• Fuel Tank Volume: 0.55 L (18.6 fl. oz.).
• Oil Tank Volume: 0.26 L (8.8 fl. oz.).
• Guide Bar Lengths: Typically 16" or 18".
• Chain Pitch: 3/8" PMM or .325".
• Weight (Powerhead): Approximately 5.2 kg (11.5 lbs).
• Ignition System: Electronic, capacitor discharge (CDI).
• Vibration Damping: STIHL Anti-Vibration system.

Controls and Components

Master Control Lever: Combines choke, throttle lock, and stop functions. Throttle Trigger: Controls engine speed. Throttle Trigger Interlock: Must be depressed to activate throttle. Chain Brake Lever: Manual activation; also activates automatically via inertia. Decompression Valve: Button to press before starting. Chain Tensioner: Side knob for adjusting chain tension.

Main Components: Cylinder, Piston, Carburetor, Air Filter, Spark Plug, Muffler, Clutch, Sprocket, Guide Bar, Saw Chain.

Fuel & Lubrication

Fuel: Mix STIHL 2-stroke engine oil with unleaded gasoline (min. 89 octane) at a 50:1 ratio. Use a clean, approved fuel container. Chain Oil: Use STIHL chain oil or a high-quality, biodegradable bar and chain oil. Do not use waste oil.

1. Always refuel in a well-ventilated area, with the engine stopped and cool.
2. Clean area around fuel cap before opening.
3. Do not smoke during refueling.
4. Check oil level before each use and refill as necessary.

Tip: Use fresh fuel mix. Do not store fuel mix longer than 30 days.

Starting & Stopping Procedure

Starting (Cold Engine):

1. Engage chain brake by pushing lever forward.
2. Press decompression valve (if equipped).
3. Set master control lever to choke position (full left).
4. Pump primer bulb (if equipped) until fuel is visible.
5. Place saw on ground, hold securely.
6. Pull starter rope sharply until engine fires (usually 2-5 pulls).
7. Immediately move master control lever to fast idle position (middle).
8. Pull starter rope again to start engine.
9. Blip throttle to disengage fast idle.

Stopping: Release throttle, allow engine to idle briefly, move master control lever to STOP position.

WARNING! Never start the saw unless the chain brake is engaged or you are certain the chain cannot contact any object.

Safe Cutting Techniques

Always plan your cut and escape path. Maintain secure footing and balance. Hold saw firmly with both hands. Let the chain do the cutting; do not force it.

Kickback Zone: Be extremely cautious of the upper quadrant of the guide bar tip. Avoid contact with this area during cutting.

Bucking & Limbing: Use proper supports for logs. Cut from top side whenever possible. Beware of tension and compression in wood.

Maintenance Schedule

Daily/Before Each Use: Check chain tension, sharpness, and lubrication. Check fuel and oil levels. Inspect for loose fasteners and damage. Clean air filter if dirty.

Weekly/After 5 Hours: Clean spark arrestor screen in muffler. Check spark plug condition and gap.

Monthly/After 20 Hours: Clean cooling fins. Check fuel filter and replace if clogged. Clean carburetor air passage.

Annually/As Needed: Replace fuel line and filter. Clean or replace air filter. Have cylinder and piston inspected by an authorized STIHL dealer.

CAUTION! Always disconnect the spark plug boot before performing any maintenance.

Warranty Information

STIHL Limited Warranty: Coverage for defects in material and workmanship. Duration varies by region and use (commercial vs. private). Proof of purchase from an authorized STIHL dealer is required. Warranty does not cover damage from misuse, neglect, improper maintenance, or use of non-STIHL parts/fuel. For warranty service, contact the authorized STIHL dealer where the product was purchased.

Troubleshooting

Service: For repairs beyond basic maintenance, contact an authorized STIHL servicing dealer. Use only genuine STIHL replacement parts.

Support: Visit www.stihlusa.com or contact your local authorized STIHL dealer.