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SERVICE MANUAL 028/038 SPECIAL TOOL

MANUAL
FOREWORD

This Service Manual covers model

028 chain saws up to machine
number 5561640 as well as later
machines unless technical infor-
mation bulletins have been issued
in the meantime with updated
repair procedures.

Models 038 have substantially the

same constructional features as
model 028 chain saws" This Serv-
ice Manual can therefore be used
for the 038 chain saws as well.

In the event of faults it is quite pos-, Repair work is made considerably Our special tool manual illustrates
sible that a single malfunction may easier if the chain saw is mounted and lists the part numbers of all
have several causes. It is, there- on assembly stand 59108503100. available machine-related tools as
fore, advisable to consult the The saw is easily attached to the well as general purpose tools for all
"troubleshooting charts" when stand by means of the two stud machines.
tracing faults" We also recommend bolts and collar nuts for bar mount-
that you make use of the exploded ing" The special tool manual is available
views in the illustrated parts lists in various languages and can be
while carrying out repair work. While on the assembly stand, the ordered by quoting the appropriate
chain saw can be swivelled into any part number listed hereunder.
This service manual and all techni- required position to suit the repair
cal information bulletins are in- in question" This not only has the German 0455 901 0023
tended exclusively for the use of advantage of keeping the compo- English 04559010123
STIHL servicing staff and dealers nent in the best position for the re- French 0455 901 0223
and must not be passed on to third pair, but also leaves both hands Spanish 0455 901 0323
parties. free for the work, and thus repre- Yugoslav 0455 901 0423
sents a considerable time-saving. Swedish 0455901 0523
Italian 0455 901 0723
Portuguese 0455 901 1223

STIHL® Andreas Stihl

Postfach 1760
0-7050 Waiblingen

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CONTENTS

1. Specifications 4 4. Ignition System 26 4. 5. 1 Checking on breaker-

4.1 Construction 26 controlled ignition 45
4.2 Operation 26 4.5.2 Adjustment on breaker-
2. Clutch, Chain Drive 4 ..2 . 1 General information 26 controlled ignition 45
and Chain Brake 7 4.2.2 Breaker-controlled 4. 5. 3 Checking on electronic
2.1 Construction magneto ignition 27 ignition 47
and operation 7 4 ..2 . 3 Bosch transistor-controlled 4.6 Magneto edge gap 48
2 . 1.1 Clutch and chain sprocket 7 magneto ignition 28
2 . 1.2 Chain brake 8 4.2.4 SEM thyristor-controlled
2.2 Troubleshooting chart 8 magneto ignition 29
2.3 Disassembly and repair 9 4 . 2.4..1 Charging the storage 5. Rewind Starter 49
2 . 3.1 Clutch 9 capacitor 29 5. 1 Construction
2.3 ..2 Chain brake 12 4.2 . 4.2Triggering the thyristor 29 and operation 49
2.4 Assembly 13 4 ..2.4..3 Ignition 30 5.2 Troubleshooting chart 49
2.4.1 Chain brake 13 4. 3 Troubleshooting chart 31 5.3 Disassembly 50
2.4 ..2 Clutch 14 4.3.1 Breaker-controlled 5.4 Replacing the starter
ignition system 31 rope 50
4 . 3 ..2 Electronic ignition 5.5 Replacing the rewind
3. Engine 15 system 32 spring 51
3.1 Construction 15 4.4 Function and repair 5. 6 Tensioning the rewind
3.2 Troubleshooting chart 15 of components 33 spring 51
3.3 Exposing the cylinder 16 4.4..1 Spark plug 33 5.7 Replacing starter rope
3.4 Disassembly of cylinder 4.4..2 Ignition lead 34 guide bush 52
and piston 16 4 . 4.3 Short-circuit wire/ground 5. 8 Routine maintenance 52
3.5 Assembly of piston wire 35
and cylinder 17 4.4.4 Short-circuit contact 36
3. 6 Disassembly of crankcase 4.4.5 Flywheel 37
- removal of crankshaft 19 4 . 4.6 Armature (Bosch)/ignition 6. AV Handle System 53
3 ..7 Installing the Crankshaft module (SEM) 39 6. 1 Construction
- assembly of crankcase21 4.4..6 . 1 Resistance test on and operation 53
3.8 Leakage testing primary winding 39 6 ..2 Repair 53
the crankcase 23 4.4..6.2Resistance test on
3 . 8.1 Pressure test 23 secondary winding 39
3 ..8.2 Vacuum test 25 4.4..6 . 3 Ignition coil tester 40
3.8 . 3 Replacing the oil seals 25 4.4..6.4 Disassembly 7. Master Control 55
and assembly 40 7.1 Construction
4.4.7 Condenser 41 and operation 55
4.4.8 Contact set 42 7 ..2 Disassembly
4.4..9 Trigger plate 44 and assembly 55
4. 5 Ignition timing 44

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8" Electric Handle Heating 10.7 Fuel line and tank vent 71
System 56 10.8 Air filter and choke 72
8,,1 Construction
and operation 56
8.2 Troubleshooting 56
8,,3 Disassembly
and assembly 58
8.3.1 Switch 58
8,,3,,2 Heating element
in pistol grip 58
8.3.3 Handlebar 58
8,,3..4 Generator 59

9" Chain Lubrication 60

9.1 Construction and
operation of oil pump 60
9,,2 Troubleshooting chart 61
9,,3 Oil tank/tank vent 62
9..4 Repair of pickup body
and valve 62
9.5 Disassembly and repair
of oil pump 63

1O" Fuel System 64

1 0,,1 Construction and
operation of carburetor 64
10"1,, 1 Operation of fuel pump 64
1 0.1,.2 Operation of carburetor 64
10,,2 Troubleshooting chart 66
10,,3 Leakage test
on carburetor 68
10..4 Disassembly
of carburetor 68
10.5 Repair of carburetor 69
10,,6 Carburetor adjustment 71
10,,6,,1 Notes for fine adjustment
of carburetor 71

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1. SPECIFICATIONS

1.1 Engine STIHL single cylinder, two-stroke engine with special impregnated
cylinder bore
Displacement: 47 cm3 (2 . 87 tu. in)
Bore:. 44 mm (1.73 in)
Stroke: 31 mm (1.22 in)
Compression ratio:: 9.5:1
Max. torque: 2 . 65 Nm (1..95 Ibf. ft) at 6000 rpm
Max. permissable engine speed: 12000 rpm
Mean idle speed: 2200 rpm
Crankshaft: Two-part, drop-forged
Crankshaft bearings: 2 deep-groove ball bearings
Crankpin: 14..4 mm (0.57 in) dia.
Big-end bearing: Needle cage
Piston pin: 10 . 0 mm (0 . 39 in) dia.
Small-end bearing: Needle cage
Rewind starter: Pawl engagement with automatic
starter rope rewind mechanism
Starter rope: 3.5 mm (0 . 14 in) dia.,
1060 mm (41.8 in) long
Clutch: Centrifugal clutch without linings,
76 mm (3 in) dia.
Clutch engages at: Approx. 3100 rpm
Crankcase leakage test:
with overpressure:: po = 0 . 5 bar (7 . 1 Ibf/in2)
with vacu u m: pu = 0.5 bar (7.1 Ibflin2)

1.2 Fuel System Carburetor: All-position diaphragm

carburetor with integral
fuel pump
Adjustment:
high-speed adjustment screw H: Open approx. 11/4 turns
low-speed adjustment screw L: Open approx . 1114 turns
(basic setting with screws initially
hard against their seats)
Carburetor leakage test
with overpressure: po = 0.4 bar (5 . 7 Ibflin2)
Fuel capacity: 0.52 L (1..1 U.S.pt)

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Fuel mixture: Fuel mix 1:40 with

STIHL two-cycle engine oil;
1:25 for other branded
two-cycle engine oils
Air filter:: Flat wire mesh filter

1.3 Ignition System 028 AV and 028 AVQ

Type: Breaker-controlled magneto
ignition system
Magneto edge gap: 4 .. " 8 mm (0,,16 . " . 0.31 in)
Air gap: 0,,2 ... 0.3 mm (0.008" " . 0.012 in)
Ignition timing: 2.2 .. ,,2,,3 mm (0.087" , ,,0.091 in)
before T..D"C.
Ignition advance angle: 27"".28°
Breaker point gap:: 0.35 ... 0.4 mm (0.014. , .0.016 in)
Condenser: Capacitance 0.15" " . 0.19 IlF
Armature: Coil resistors
Primary Secondary
0..7 ... 1,,00 7..7 ... 10.3 kQ
028 AVE
Type: Transistor-controlled (breaker-
less) magneto ignition system
Air gap: 0.2. " . 0,,3 mm (0,,008,. , 0.012 in)
Ignition timing:: 2.6 mm (0,,1 in) before T.D.C"
at 8000 rpm
Ignition advance angle: 30° at 8000 rpm
Armature: as 028 AV/028 AVQ

028 AVEQ
Type: Thyristor-controlled (breaker-
less) magneto ignition system
Air gap: 0,,2 ... 0.3 mm (0.008 ... 0,,012 in)
Ignition timing: 2.6 mm (0,,1 in) before T.D.C"
at 8000 rpm
All Models
Spark plug (suppressed): Bosch WSR 6 F or
Champion RCJ 6 Y
Heat range: 200
Electrode gap:: 0.5 mm (0,,02 in)
Spark plug thread: M 14x1..25; 9.5 mm (0.37 in) long

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Tightening Torques Crankshaft nut

1.4 30 Nm (22 Ibf. ft)
(ignition side) M 8 x 1:
Hub/spider (output side):, 50 Nm (37 Ibf. ft)
M 5 socket head screws: 8 Nm (6 Ibf.. ft)
M 5 cheese-head screws: 5 Nm (3,,7 Ibf. ft)
M 4 cheese-head screws:, 2.5 Nm (1.8 Ibf.. ft)
5 Nm (3.7 Ibf.. ft)
M 5 nuts:
25 Nm (18,,4 Ibf.. ft)
Spark plug:

Important: The M 5 x 12 screws on the front handguard and the

M 4 x 8 screws on the spider are fitted with LOCTITE.

STIHL Duromatic guide bars

Cutting Attachment Guide bars:,
1.5 with stellite-tipped bar nose;
STIHL Rollomatic guide bars
with sprocket nose. Both types
with corrosion resistant finish
and induction hardened track
Duromatic 40 and 45 cm
Bar lengths:
(16 and 18 in)
Rollomatic 32, 37, 40 and 45 cm
(13,14.6,16 and 18 in)
0.325" (8,,25 mm) pitch
Chain:,
7 -tooth for 0.325" chain
Chain sprocket::
16.4 m/s (53.8 ft/sec) at 8500 rpm
Chain speed:,
Speed-controlled oil pump
Chain lubrication:,
with lift plunger, operative
only when chairi is running
8 cm 3 /min (0,,49 cu. in/m in)
Oil delivery rate:
at 6000 rpm
Oil tank capacity:, 0.3 L (0,,63 U"S"pt)

AV/AVE AVQ/AVEQ
1.6 Weights Model:
Dry weight with 32 cm
6,,5 kg (14.3 Ib) 6,,6 kg (14.5 Ib)
bar and chain:,

STIHL rescue kit 028 11189005000

1,,7 Special Accessories 11180071050
Gasket set 028

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2. CLUTCH,
CHAIN DRIVE AND
CHAIN BRAKE

2.1 Construction and

Operation

2. 1. 1 Clutch and Chain Sprocket

Chain brake engaged Chain brake released

The transmission of power from the

engine to the saw chain is effected
via a centrifugal clutch . O~ "Quick-
stop" models, the centrifugal clutch
incorporates an isolating clutch
which isactuated by the chain brake.

On the Quickstop version the hub

screwed to the crankshaft is the
clutch element which absorbs the
torque and acceleration of the
crankshaft.. It is essential that the
hub is always tightened down to the
specified torque . The clutch spider The centrifugal clutch has three the clutch shoes begin to make con-
is supported on the hub by a needle clutch shoes without linings . The tact with the clutch drum at an en-
sleeve and located axially with a clutch drum and chain sprocket are gine speed of approx . 3100 rpm
circlip . The driving plate is located separate components. The spur (engagement speed) . The clutch
on thethree lugs of the clutch spider gear which drives the oil pump is a engages fully above this speed . The
and can move axially while remai- ring-gear, positively mounted to the correct idle setting on the carbure-
ning in constant mesh with the hub of the clutch drum . The chain tor is therefore essential in order to
spider . The flat spring between the sprocket has two integrally cast lugs insure that the clutch engagement
spider and driving plate presses the which engage in corresponding re- speed is not reached when the en-
driving plate against the release cesses on the drum hub . As the lugs gine is idling .
plate; this means that the internal have odd sizes, the chain sprocket
teeth of the driving plate are always can only be fitted in one position .
in mesh with the teeth of the hub
when the chain brake is released, When the engine is running at idle
and thus provides positive trans- speed the clutch shoes are also in
mission of engine torque to the the idle position, because the ten-
clutch spider . When the chain brake sion of the clutch spring is greater
is actuated, the release plate dis- than the centrifugal force . As engine
engages the driving plate from the speed increases, centrifugal force
hUb . The clutch spider and hub can presses the clutch shoes outwards
then rotate independently. against the clutch drum and thus
transmit engine torque positively
via the chain sprocket to the saw
On the standard version the clutch chain .
spider assumes the function of the
hub and must therefore always be The preload and strength of the
tightened to the specified torque . clutch spring are designed so that

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2,,1,,2 Chain Brake

The chain brake is a spring-loaded The chain brake is released (reset) The chain brake is actuated by mo-
band brake without linings" Its main by pulling the handguard back ving the handguard towards the bar
components are the brake band, against the handlebar" This move- nose" This movement unlatches the
tension spring, handguard and re- ment is transmitted via a lever brake lever and causes the brake
lease plate - which operates the system which preloads the tension band to be clamped around the
isolating clutch" spring and disengages the brake clutch drum by the force of the pre-
band. At the same time the release loaded brake spring" The release
The chain brake is actuated by plate moves back and allows the plate simultaneously disengages
means of the handguard which can driving plate to engage in the teeth the driving plate from the hub and
be used to release and engage the of the hub" The brake lever, which is interrupts the flow of power between
brake" connected to the tension spring, the crankshaft and the centrifugal
brake band and release plate, is clutch" Clutch drum and saw chain
locked in the idle position by the are brought to a standstill within a
relay lever. fraction of a second even if the en-
gine continues running at high
speed"

2.2 Troubleshooting Chart

Fault Cause Remedy

Saw chain turns at idle speed Engine idle speed too high Readjust at idle speed adjustment
screw
Clutch spring stretched or fatigued, Renew clutch spring
spring hooks broken

Excessive chain sprocket wear Incorrect chain tension Tension saw chain properly

Chain stops in mid-cut even with Isolating clutch worn Renew hub and driving plate
engine at maximum speed -
Isolating clutch disengages Flat spring broken Renew flat spring
during cutting

Isolating clutch does not re-engage Engine idle speed too high Readjust at idle speed adjustment
after releasing chain brake screw
Flat spring broken Renew flat spring

Saw chain does not stop imme- Tension spring broken Renew tension spring
diately when chain brake is engaged

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2,,3 Disassembly and Repair

2,,3,,1 Clutch

Top:
Removing the side plate

Top: Center: Top:

Chain brake released Releasing the cover Removing the spur gear

Bottom: Bottom: Bottom:

Pressing out the retaining washer Ring-gear removed Clutch drum and needle sleeve removed

First remove chain sprocket cover Remove the inner side plate - se-
and cutting attachment.. cured with a single M 4 x 12 cheese-
head screw" Unscrew the five
M 4 x 12 cheese-head screws and
The chain brake must be released take off the cover" Now remove ring
before removing the chain sprocket gear from clutch drum hub and the
Use a screwdriver, about 5 mm spur gear (with worm) from the oil
wide, to press the retaining washer pump shaft by turning it clockwise.
out of the annular groove in the Pull clutch drum and needle sleeve
crankshaft. The thrust washer, off the crankshaft
chain sprocket and needle sleeve
can now be pulled off the cranks-
haft

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Top:
Driving plate removed
Top:
Removing the circlip Center: Top:
Locking screw 11071911200 Special socket 11188931300
Bottom:
Clutch, flat spring and needle sleeve Bottom: Bottom:
Locking screw inserted Unscrewing the hub
removed

Disassembly differs on the Quick- spark plug and fit locking screw
stop and standard versions from this 11071911200 in the spark plug hole
and tighten down by hand . Use spe-
stage onwards.
cial socket 11188931300 to unscrew
the hub. Remove washer from
On the Quickstop version, first re- behind hub .
move the circlip which locates the
clutch spider on the hub . The clutch
with flat spring and needle sleeve
can now be pulled off the hub . If the
hub has to be removed, first remove
the driving plate and block the
crankshaft.. To do this, unscrew

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Top:
Removing cover plate

Bottom:
Unscrewing the clutch spider Clutch spring in spring recess Pressing clutch spring into position

The crankshaft must also be blo- hooks are in the center of the clutch
cked with locking screw11071911200 shoe" Now fit the three olutch shoes
in order to remove the clutch spider on the arms of the spider so that the
on the standard version, Use' a spring recesses face away from the
19 mm cranked ring wrench to un- triangular plate on the spider" Grip
screw the clutch spider and then re- the clutch spring with both thumbs
move the dished cover plate" and push it into the spring recesses
of the other two clutch shoes.

Caution: The hub and clutch spider

have left-hand threads - unscrew Refit the cover plate on the Quick-
them clockwise. stop clutch" The three M 4 x 8
cheese-head screws must be secu-
red with LOCTITE"
Wash all parts of the clutch, inclu- Use the following procedure to re-
ding the needle cages, in clean place the clutch spring, clutch shoes
gasoline and blowout with com- or spider:
pressed air if available" Also clean
crankshaft stub"
First unscrew the cover plate from
the spider (Quickstop only) and then
Always replace damaged or worn remove the clutch shoes"
parts,

Toassembletheclutch, first position

the clutch spring in the spring recess
of one clutch shoe, so thatthe spring

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2.3,,2 Chain Brake

Top:
Removing retaining washer

Center and Bottom:

Unscrewing the handguard
Detaching the tension spring
The spring guide pins in the crank-
case must be replaced if they are
damaged"

These screw pins must be bonded

in position to prevent them loose-
ning in operation" To do this, use a
suitable solution (trichlorethlene,
diluted nitro or similar) to complete-
ly degrease the threads in the crank-
case and on the pins themselves,
Then coat the threads of the screw
pins with a little adhesive - 101, part
number 0786 111 1101, (LOCTITE
242) - and screw them into the
The clutch drum must be removed crankcase, Tighten to a torque of 4,,9
before the brake band can be disas- Nm (0.5 kpm).
sembled" To do this, engage the
chain brake and detach the tension It is essential to use a suitable
spring" Remove retaining washer screwdriver with a tip which fits
from brake lever's pivot pin and snugly in the slot of the pin in order
carefully withdraw the brake lever" to avoid damaging the pin materiaL
Collect the washers and helical A 1 x 6.5 screwdriver in accordance
spring on the brake band's pivot pin" with DIN 5265 is recommended for
The other end of the brake band can
this purpose"
now be prised out of its seat in the
crankcase"

Take out the clutch before removing

the release plate" Remove the re-
taining washers, washers and heli-
cal springs from the guide pins and
take the release plate out of the
crankcase"

Unscrew the handguard (the chee-

se-head screws will be difficult to
remove because they are fitted with
LOCTITE) and then take out the
actuating lever, relay lever and tor-
sion spring"

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2..4 Assembly

24..1 Chain brake

Top:
Brake band and brake lever in position

Center:
Top: Special assembly tool
Torsion spring and relay lever in position 11178900900
Bottom: Bottom:
Actuating lever fitted Seat for brake band Attaching the tension spring

end of brake band in its seat in the

crankcase and insert pivot pin of
brake lever in the loop of the brake
band . Fit washer, helical spring and
washer on the pivot pin of the brake
lever . Push lever onto pivot pin and
locate pin in slot of release plate at
the same time. Now secure brake
lever with retaining washer and at-
tach the tension spring using the
special assembly tool.

First fit the relay lever, actuating

lever and handguard. The ends of
the torsion spring must engage in
the hole in the crankcase and the
actuating lever . The M 5 x12 cheese-
head screws must be secured with
LOCTITE.

Now fit release plate in crankcase

so that its slots locate overthe guide
pins . Fit washer, helical spring, wa-
sher and retaining washer on the
guide pins in that order . Locate bent

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2..4.2 Clutch

Top: Bottom:
Tightening the hub with a torque wrench Flat spring fitted on spider lugs

onto the crankshaft and tighten to a

torque of 49.0 Nm (5.0 kpm) using
a torque wrench with a 19 mm socket.

It is essential to observe the speci-

fiedtorqueasthespidermayother-
wise loosen in operation.

The assembly procedure is now the

same for both versions"

Lubricate needle sleeve of clutch

drum with antifriction grease and fit
it on the crankshaft..
First degrease the threads on the
crankshaft and hub (Quickstop) or Push clutch drum onto crankshaft
clutch spider (standard) with a suit- and needle sleeve and then fit spur
able solution (trichlorethlene, dilu- gear onto oil pump shaft. Slip ring
ted nitro or similar)" gear onto hub of clutch drum.

The initial assembly operations are Finish off by fitting cover and chain
different on the Quickstop and stan- sprocket; remove the locking screw,
dard versions . fit and tighten down the spark plug"

On the Quickstop version, fit the

flange washer on the crankshaft,
screw hub counter-clockwise onto
the crankshaft and tighten to a tor-
que of 49.0 Nm (5 . 0 kpm) using the mustfaceawayfromtheclutch. Now
special socket 11188931300 and a push clutch together with greased
torque wrench" needle sleeve onto the hub and turn
backwards and forwards until the
It is essential to observe the speci- clutch spider lugs engage in the dri-
fied torque as the hub may other- ving plate.. Fit circlip to secure
wise loosen during operation. clutch.

Engage the driving plate on the teeth On the standard version, fit cover
of the hub" The chain brake must be plate on the crankshaft so that the
in the released condition during this raised outer diameter faces away
operation, Fit flat spring on lugs of from the crankcase" Screw spider of
clutch spider; the raised spring tabs clutch assembly counter-clockwise

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3" ENGINE

3. 1 Construction

Series 028 chain saws are powered at the other side, hermetically seal machine finished . For this reason a
by an air-cooled, single cylinder the crank chamber. replacement crankshaft can only
two-stroke engine . be supplied complete with connec-
The connecting rod, also drop-for- ting rod and needle sleeve.
The crankcase is a two-part pres- ged, is supported on needle cages
sure die-casting made of a special both on the crankpin and the piston Cylinder and piston are made of a
magnesium alloy.. The two-part pin. Once the needle cage and the special aluminum alloy" The cylin-
drop-forged crankshaft is supported connecting rod have been fitted, the der bore is impregnated in a special
in two deep-groove ball bearings . two halves of the crankshaft are process .
Two oil seals, in the crankcase atthe pressed together to form a torsio-
ignition side and in the ball bearing nally rigid assembly and then

3.2 Troubleshooting Chart First check fuel supply, carburetor,

air filter and ignition system before
looking for faults on the engine .

Fault Cause Remedy

Engine does not start easily, Oil seals in crankcase Replace oil seals
stalls at idle speed, but operates leaking
normally at full throttle
Elbow connector leaking Seal or replace elbow connector

Crankcase damaged (cracks) Replace crankshaft

Engine does not deliver full power Secondary air seepage into engine Mount elbow connector correctly
or runs erratically through poorly mounted or or replace
faulty elbow connector

Piston rings leaking or broken Replace piston rings

Engine overheating Insufficient cylinder cooling . Thoroughly clean all cooling air
Air inlet opening in fan housing openings
blocked or cooling fins
on cylinder plugged

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3,,3 Exposing the Cylinder 3.4 Disassembly of Cylinder

and Piston

Top:
Top: Removing the wire retainers
Removing the shroud
Bottom:
Bottom: Pushing out the piston pin
Unscrewing the muffler Removing the cylinder base screws

Drain fuel and oil tanks, Remove the

carburetor (see 10.4) and unscrew
the four cylinder base screws" Care-
fully pull the cylinder off the piston
and press the elbow connector for-
wards and ,out of the tank housing"

Before removing the piston it must

be decided whether or not the
crankshaft is to be removed, Le. the
wooden block used to lock the
crankshaft - to facilitate removal of
the flywheel and hub (Quickstop) or
First remove carburetor box cover, clutch spider (standard) - must be essential to counterhold the piston
unscrew spark plug and take off the fitted be1ween the crankcase and to insure that no jolts are transmitted
shroud and two-part muffler" the piston" to the connecting rod" Remove the
piston"
The cooling fins of the cylinder are To remove the piston, first take out
now easily accessible and can be the two wire retainers and press the
cleaned thoroughly" Check for da- piston pin out of the piston and nee-
mage (cracks, broken cooling fins, dle cage by means of drift
etc), 11108934700.

If the piston pin is stuck as a result

of carbonization, tap it out lightly
with a hammer and the drift. It is

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3..5 Reassembly of Piston

and Cylinder

Top:
Wooden assembly block, ring compressor
and clamping strap

Arrow and" A" point towards exhaust Bottom:

port Fitting the piston pin Elbow connector in position

If the cylinder has to be replaced the The piston pin must move freely in
new cylinder must always be instal- its bore. Never use force during
led with a matching piston" Replace- assembly.
ment cylinders are only supplied
complete with piston"
Insert the two wire retainers and
If only the piston is to be renewed, make sure that they are properly
every replacement piston (marked seated,
"B") can be used with any cylinder"

Mounting of the cylinder is best car-

Before installing the piston, lubri- ried out using the wooden assembly
cate the needle cage with oil and block and the ring compressor
insert it in the connec!ing rod" Posi- 1113 893 4900 or clamping strap
tion piston on connecting rod sothat 00008932600" with hose clamp, making sure that
the stamped markings (arrow and A) the clamp is correctly seated and
point towards the cylinder exhaust does not distortthe elbow connector
port (towards tip of guide bar)" Now The elbow connector must be fitted when tightened down.
fit piston pin in piston and connec- if a new cylinder is used" To insure
ting rod (needle cage)" To do this, a perfect seal, coat the inside of the
push assembly drift through piston elbow connector's neck with sea-
bore and connecting rod to align ling paste 0783 810 1101" Fit elbow
both bores concentrically" Fit piston connector on the intake stub so that
pin on spigot of assembly drift and it faces upwards (towards cylinder
slide into piston" Gently move piston head) and the moulding seam is
to and fro to ease insertion of piston vertical (parallel with cylindercenter
pin, line)" Then secure elbow connector

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18

Top:
Piston on wooden assembly block

Bottom: Tightening cylinder base screws with

Piston rings correctly positioned Fitting the cylinder torque wrench

Insert the four M 5 x 16 socket head

screws in the cylinder mounting
holes . Using the ring compressor or
clamping strap, compress the piston
rings while making sure they are
correctly positioned.. Fit cylinder
over the piston with the exhaust port
facing in the direction of the guide
bar tip . During this process make
sure that the cylinder is properly
aligned, Le. the outer edges of the
cooling fins must be exactly parallel
with the outer edge of the crankcase
atthe sprocket side . Ifthis alignment
Fit new cylinder gasket on the crank- is not carried out, the piston rings Insert sleeve in elbow connector
case. Lubricate piston and piston may break . The ring compressor is and then refit carburetor (see 1004),
rings with oil. Place wooden block pushed downwards as the piston muffler, shroud, spark plug and car-
on the crankcase so that piston is rings move into the cylinder . Re- buretor box cover .
resting on it.. move wooden assembly block and
ring compressor.. Push flange of
elbow connector through the bore
Position each piston ring so that the in the tank housing (do not use a
radii at the ring gaps locate against sharp tool forthis purpose) and align
their respective fixing pins in the the cylinder gasket and cylinder .
piston grooves. Tighten down the four cylinder base
screws to a torque of 7 . 8 Nm
(0 ..8 kpm) in a diagonal pattern..

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